Gasification devices and methods

ABSTRACT

A device for converting one or more feed fuel to syngas is disclosed that comprises a metallic crucible for holding an electrically conductive material and at least one electric heater in the vicinity of the crucible. The electric heater comprises a coil for providing a flow of current through the at least one electric heater so as to cause melting and heating of the electrically conductive material to form a molten material disposed within the metallic crucible. Furthermore, the device comprises a liquid cooling arrangement for the crucible, at least one feeding conduit for providing a flow stream of the one or more feed fuel to be delivered into contact with the molten material to convert at least a portion of one or more feed fuel to syngas and at least one supply conduit for delivering the syngas to the exterior of the crucible.

The current specification relates to devices and methods for gasification and in particular to gasification devices using a molten metal for heat transfer.

An example of a gasification device using an induction coil for obtaining a molten metal is disclosed in the U.S. Pat. No. 5,537,940 issued to Nagel, Sparks and McGeever.

SUMMARY OF THE APPLICATION

A device for converting one or more feed fuel to syngas, comprises a metallic crucible for holding an electrically conductive material, at least one electric heater in the vicinity of the crucible, the at least one electric heater comprising a coil for providing a flow of current through the at least one electric heater so as to cause melting and heating of the electrically conductive material to form a molten material disposed within the metallic crucible, a liquid cooling arrangement for the crucible, at least one feeding conduit for providing a flow stream of the one or more feed fuel to be delivered into contact with the molten material to convert at least a portion of one or more feed fuel to syngas, and at least one supply conduit for delivering the syngas to the exterior of the crucible.

In other words, the device of the application comprises a substantially metallic crucible which encloses a hollow with a metallic surface for holding a metallic material in the hollow, at least one heater, the at least one heater being disposed in proximity to the metallic crucible, the at least one heater being adapted to provide heating of the crucible, a fluid cooling arrangement disposed in proximity to the metallic crucible, at least one feeding conduit, the feeding conduit extending between the outside of the crucible and the inside of the crucible, and at least one supply conduit, the supply conduit extending between the inside of the crucible and the outside of the crucible.

The device of the application can also comprise a holder unit with a metallic surface that defines a hollow for holding a molten metallic material, at least one heater unit disposed in proximity to the holder for heating the hollow, at least one feeder unit for providing a flow stream of one or more combustible material to be delivered into the hollow, a cooler unit for cooling the holder, the cooler unit being disposed in proximity to the holder, and at least one supply means for delivering a gas from inside the crucible to the outside of the crucible.

The gasification method of the application for converting one or more feed fuel to syngas, comprises the following elements:

-   -   placing an electrically conductive material within a metallic         crucible;     -   heating the electrically conductive material to form a molten         material disposed within the metallic crucible and maintaining         the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of the one or more feed fuel into         contact with the molten material, thereby converting at least a         portion of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible.

In other words, the gasification method of the application for converting one or more feed fuel to syngas, comprises the following elements:

-   -   placing a metallic material within a hollow such that it is in         contact with a metallic surface of the hollow;     -   melting the metallic material to form a molten metallic material         and maintaining the molten metallic material in a molten state;     -   cooling the metallic surface with a fluid;     -   bringing one or more flow stream of one or more         hydrocarbon-containing material into contact with the molten         metallic material;     -   extracting reaction gas from the hollow.

Further, the application provides a method for refining or processing hydrocarbons in an oil refinery plant, comprising placing a metallic material within a hollow such that it is in contact with at least a part of the interior wall surface of the hollow, melting the metallic material to form a molten metallic material and maintaining the molten material in a molten state, bringing one or more flow stream of one or more feed fuel material into contact with the molten metallic material, and extracting reaction gas from the hollow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional view of an embodiment of a device for converting a feed fuel according to a first exemplary embodiment of the present specification,

FIG. 2 illustrates a cross sectional view of the metallic crucible of FIG. 1,

FIG. 3 illustrates a cross section partial view of the electrically insulating material interposed between the metallic crucible and the induction coil,

FIG. 4 illustrates a further embodiment of an induction coil that is provided with an insulating material,

FIG. 5 illustrates a cross-sectional view of a further embodiment of a gasifier for converting feed fuel to synthesis gas that is provided in an outer container,

FIG. 6 illustrates an enlarged cross section of FIG. 5,

FIG. 7 illustrates a crude oil refinery with the corresponding plant block schematics, which is adapted for a communicative connection to a gasifier of FIG. 1 to 6, 11, 13 or 14,

FIG. 8 illustrates a crude oil refinery similar to the refinery of FIG. 7, which comprises a parallel processing of a reduced crude feedstock in a vacuum distillation column,

FIG. 9 illustrates a hydrocracking plant of an oil refinery and the corresponding plant block schematics, which is adapted for a communicative connection to a gasifier of FIG. 1 to 6, 11, 13 or 14,

FIG. 10 illustrates a vacuum distillation section of an oil refinery of FIG. 8 or FIG. 9 with the corresponding plant block schematics,

FIG. 11 illustrates a further embodiment of a gasifier 10′ with a tilted crucible, and with feeding conduits,

FIG. 12 illustrates a flow scheme for a syngas production with a gasifier according to the present specification, and

FIG. 13 illustrates an embodiment of the present specification comprising a flue gas source that is connected to a gasifier,

FIG. 14 illustrates a metal refining reactor for refining a metal containing material and gasifying a feed fuel,

FIG. 15 illustrates heat exchange units for heat exchange between a gasifier and a distillation tower,

FIG. 16 illustrates units for material exchange, information exchange and electric energy exchange between a gasifier and a distillation tower, and

FIG. 17 illustrates a crude oil distillation with appliances which are powered by a syngas driven electric generator.

For the sake of brevity, some references are referred to by an abbreviated title. The respective complete titles and source information can be found in the references section at the end of the specification.

FIG. 1 shows a cross-sectional view of a gasifier 10 device for converting a feed fuel according to a first exemplary embodiment of the present application.

The gasifier 10 of FIG. 1 comprises a metallic crucible 40 that is covered by a cover 60, and surrounded by a cylindrical shell 41. Furthermore, the gasifier 10 comprises several feeding conduits 50, 51, 52 and a downstream application conduit 140. Providing more than one feeding conduits contributes to the versatility of the gasifier 10, because more than one feed fuel material source can be connected at the same time.

The crucible 40 is surrounded by a helical induction coil 120. Arranging the helical induction coil 120 at the outside of the crucible 40 extends its service life as compared with placing the helical induction coil 120 inside of the crucible 40.

Furthermore, a cooling arrangement for the crucible is provided in proximity to and/or within the crucible. Different embodiments of cooling arrangements are shown in FIG. 2 and FIGS. 5 and 6. Cooling of the substantially metallic crucible 40 can be provided such as to cause a thin layer of pre-determined thickness of the molten and electrically conductive charge material inside the crucible 40 to be solidified or semi-solidified so as to cause a protective layer to be formed to increase and enhance the overall operational lifespan of the crucible 40. This mode of operation can be applied to all the embodiments of the application that have a metallic crucible.

The metallic crucible 40 comprises a bottom floor 30 and a cylindrical side wall 31. The bottom floor 30 and the cylindrical side wall 31 are integrally connected with each of the to ensure a homogenous material between bottom floor 30 and side wall 31.

A melt 90 is disposed within a hollow region 32 defined by the crucible 40. In the context of the current specification, the melt is also referred to as “molten material” or as “electrically conductive material”.

The helical induction coil 120 is placed in proximity to the metallic crucible 40 forming a multiplicity of turns. A power supply circuit, which is not shown in FIG. 1, delivers an alternating electric current power to the induction coil 120, the alternating current power having a pre-determined frequency. One or more induction coils 120 provide an induction heater according to the present specification.

One example of such a power supply circuit having a pre-determined frequency of alternating voltage applied to the induction coil to cause heating and melting of electrically conductive materials can be found in “Heat treating, American Society for Metals”, “Haimbaugh, Induction Heat Treating”, “Principles of Power Electronics”, “Advanced Melting Technologies”, “Inductotherm information brochure”.

Another reference relating to the principles of induction heating and melting can be found in “Induction Furnace—A Review”.

According to the embodiment of FIG. 1, the induction coil 120 is embedded into the cylindrical shell 41. The cylindrical shell 41 may be made of a different material than that of the metallic crucible of 40, 31, 30 and 44.

In a further embodiment, the exterior wall surface of the metallic crucible can be surrounded with a layer of heat insulating material to minimize heat loss from the metallic crucible to its immediate and or ambient environment.

The cylindrical shell 41 is made of a magnetically permeable heat insulating material and/or of several a magnetically permeable heat insulating materials that essentially do not impair the magnetic field which is generated by the induction coil 120.

The shell 41 comprises a shell bottom 42 which is in close contact for thermal insulation of the metallic crucible and to reduce heat loss from the metallic crucible 40, 31, 30 and 44. with the bottom floor 30 of the crucible 40. The crucible 40 and the shell 41 are also referred to as “reactor vessel 43”. The reactor vessel 43 comprises the bottom floor 30, which is also referred to as “internal bottom surface”, an internal lateral surface 44, the shell bottom 42, which is also referred to as “external bottom surface” and a shell side wall 45, which is also referred to as “external side surface”.

The cover 60, which comprises a conduit 140, forms a substantially sealed to make the reactor vessel gas tight) containment device with the metallic crucible 40. The conduit 140 comprises a passage line 80, which is a receiving region for a syngas stream 81. “Synthesis gas,” or “syngas,” as according to the present specification generally refers to a mixture comprising carbon monoxide (CO) and hydrogen (H2) produced by gasification in a gasifier, possibly with CO2 and other components in small amounts. A “gasifier,” as defined herein, refers to a reaction environment wherein a carbon carrying feedstock material is converted into a gas through the action of heat and, possibly, one or more reactive gases such as oxygen, air, carbon dioxide (CO2), and/or steam.

The feed conduits 50, 51 are arranged at a bottom—to increase the residency time of feed contacting the melt during operation—of the metallic crucible to deliver one or more feed fuel material (not shown) into fluid contact with the melt 90. In other embodiments, the feed conduits 50, 51 can be arranged in other locations such as through the side walls of the metallic crucible 40, or from the freeboard space above the surface of the melt 90, for reducing manufacturing time and allow feed fuel material delivery conduits to be easily replaceable even during operation of the present invention. An example of such an overhead conduit is provided by the overhead lance conduit 52 of FIG. 1. A slag channel 110 is provided at the cylindrical side wall 31 of the crucible 40, to reduce manufacturing time and allow feed fuel material delivery conduits to be easily replacement even during operation of the present invention.

The reactor vessel 10 is substantially sealed to allow for high pressure operation of the reactor during gasification except for the slag channel 110 and for the passage line 80 to the downstream application conduit 140, to allow for slag to be withdrawn from the reactor to a remote site by pressure difference).

In an optional embodiment, the downstream application conduit 140 is sealed to ensure pressurized operation within the conduit 140 by means of appropriately configured flow valves which are not shown in FIG. 1. A feed fuel, symbolized by CxHx, which can be a liquid, a solid or a gas, and an oxidant gas to provide for any number of desired feed fuel to oxidant ratio mixtures, such as O2, N2, H2O, is provided from above or below the melt surface through the overhead lance conduit 52 depending on the required and or desired syngas quality. Depending on the ash and Sulphur composition of the feed, the slag layer 100 is formed during gasification of the feed into syngas 80, and at least a portion of the slag layer 100 is periodically removed by draining the slag layer 100 through the slag channel 110. The draining may involve tilting the angle of the crucible 40 into a pre-determined tilted orientation or maintaining the crucible 40 in a pre-determined tilted orientation, as shown in FIG. 10 for example.

According to the application, the gasifier comprises at least one inlet conduit, such as the overhead lance conduit 52 or the feed conduits 50, 51, which extends into the inner hollow region 32 of the metallic crucible 40 for placing a feed fuel into fluid contact with at least a portion of an electrically conductive charge material disposed within the crucible 40. the electrically conductive charge material in the crucible 40 comprises, among others, metals such as cast iron, copper, steel, tin, zinc, or a combination thereof, or derivatives thereof, such as alloys with other metals and/or carbon.

The gasifier 10 comprises at least one outlet conduit in fluid communication with the metallic crucible 40, such as the downstream application conduit 140. Furthermore, the gasifier comprises a cooling means for cooling the crucible 40 which is not shown in FIG. 1. A cover 60 in which the downstream application conduit is inserted, is provided on top of the metallic crucible 40. The overhead lance conduit 52 passes through an opening of the cover 60.

The shell can be made of aluminium, of other non-corrosive and temperature resistant lightweight materials or of a combination of these materials together with other materials such as strength increasing filaments. The sheet material is permeable for the magnetic field which is generated by the heating coil 120.

FIG. 2 shows an enlarged view of the crucible 40 with three different cooling arrangements which can be used alone or in combination in the crucible of FIG. 1.

The metallic crucible 40 comprises a plurality of hollow passageways 211, 214 within the material body of the crucible 40. One cooling arrangement comprises hollow passageways 211 in a side wall 44 of the crucible 40. A further cooling arrangement comprises hollow passageways 214 in a bottom portion 30 of the crucible 40 while still a further cooling arrangement comprises hollow cooling conduits 310 which form a plurality of turns surrounding the outer wall surface of the metallic crucible 40. In another embodiment, one or more hollow conduits similar to the hollow conduit 310 surround the outer surface of the bottom floor 30.

The hollow passageways 211 are in fluid communication with an external fluid circulation circuit comprising through a cooling fluid supply conduit 210 and a cooling fluid discharge conduit 212. Similarly, the hollow passageways are in fluid communication with an external fluid circulation circuit through a cooling fluid supply conduit 213 and a cooling fluid discharge conduit 215.

The hollow passageways 211, 214 and the hollow cooling conduits 310 circulate a coolant fluid. One stream of coolant fluid is symbolized by arrows 216. A further stream of coolant fluid is symbolized by arrows 217. The hollow passageways 211, 214 and the hollow cooling conduits 310 may be arranged in one of various geometries and shapes, such as a series of helical turns, a series of “U” shaped turns or other shapes and geometric configurations.

In further embodiments, more than one cooling fluid supply conduit and more than one cooling fluid discharge conduit is provided per cooling arrangement.

The crucible 40, which comprises the internal wall surfaces 30 and 44, is made of a metallic material. The metallic material can comprise a metal or metal alloy which may comprise, among others, copper, steel, Inconel, iron, tungsten, titanium, molybdenum, or alloy derivatives thereof, or a combination thereof.

In the embodiment of FIG. 2, a bottom section 30 of the metallic crucible 40 is thicker than a side section 44 of the metallic crucible. The side section 44 tapers in direction from the bottom section 30 to an upper end of the metallic crucible 40, such that an outer side surface of the metallic crucible 40, which is opposite to the inner side surface 44, is essentially rectangular to the inner bottom surface 30 and such that the inner side surface 44 is inclined by a small angle, for example by an angle of 1 degree 30 minutes plus or minus 6 minutes, with respect to a vertical direction that is defined by a vertical to the bottom surface 30. Furthermore, a transition region between the inner side surface 44 and the bottom surface 30 is rounded.

The inner space 32 of the metallic crucible 40 defines a region, or a hollow, in which a metallic charge is placed within and subsequently melted and formed into a melt 90 shown in FIG. 1. The metallic crucible 40 of the gasifier 10 comprises a bottom wall 30 and a vertical wall 44 to hold melt 90 and molten slag 100. A multiplicity of hollow passageways 211, 212 are configured and arranged within the wall 44 of gasifier 10, and a cooling fluid having a pre-determined temperature range is circulating within the crucible 40 to regulate the temperature of the metallic crucible areas 30, 44 and any other surface that is in fluid contact with the melt 90, the molten slag 100, or with a mixture thereof.

During operation according to the present specification, the coolant fluid, which circulates within the external fluid circulation circuit and passes through the plurality of hollow passageways 211, 214, cools and regulates the temperature of the metallic crucible 40, including the bottom floor 30. Likewise, the multiplicity of hollow cooling conduits 310 causes the flow of the coolant fluid (not shown) to perform cooling and regulation of the metallic crucible 40.

A circulating cooling fluid flows through the hollow passageway 211, 214 and the hollow cooling conduits 310 and transfers heat from the material body of the crucible 40 to the circulating cooling fluid. The temperature of the cooling fluid is adjusted for regulating the operating temperature of the crucible 40. Regions in which heat is transferred are for example the internal lateral surface 44, the shell side wall 45, the bottom floor 30 and the shell bottom 42.

In one embodiment, the metallic crucible is cooled to a desired temperature range of between 200 degrees Celsius to 800 degrees Celsius.

In another embodiment, the metallic crucible is cooled to a desired temperature range of between 120 degrees Celsius to 500 degrees Celsius.

In another embodiment the metallic crucible is cooled to a desired temperature range of between 100 to 300 degrees Celsius.

the metallic crucible is cooled to the desired temperature ranges (200 to 800 degrees c, 120 to 500 degrees c, 100 to 300 degrees c) to maintain the material strength of the crucible and to eliminate or minimize material fatigue during prelonged operation.

the metallic crucible is also cooled to the desired temperature ranges (200 to 800 degrees c, 120 to 500 degrees c, 100 to 300 degrees c) to maintain a layer of semi-solidified melt at the interior wall surface of the crucible, thereby having a protective layer to increase overall lifespan of the crucible during prelonged operation.

The cooling can be arranged such that a layer of the molten and electrically conductive charge material inside the crucible 40 remains solidified or semi-solidified so as to cause a protective layer to be formed inside the crucible 40.

The present specification discloses a metallic crucible which has a multiplicity of passageways containing a flow of cooling fluid, wherein the cooling fluid is introduced at the inlet of the multiplicity of passageways at a second desired temperature range to cause the metallic crucible to be operating within a first desired temperature range, and cooling fluid exits through the multiplicity of passageways at a third desired temperature range during operation.

In another embodiment of the present specification, the first desired temperature range, second desired temperature range, third desired temperature range, or combinations thereof, are measured by one or more sensors in communication with at least one remote processor operable to further control the flow rate of the cooling fluid, the second desired temperature range of cooling fluid or a combination thereof, so as to cause the metallic crucible to be operating within first desired temperature range.

In another embodiment of the present specification, the cooling fluid is introduced at second desired temperature range into the multiplicity of passageways within the body of metallic crucible that holds the electrically conductive melt, so as to cause at least a portion of electrically conductive melt to form a layer of partially solid or solid material within at least a portion of the inner wall surface, the bottom inner surface, or a combination of the metallic crucible's inner surfaces further lengthening the lifespan of the metallic crucible.

To reduce the occurrence of inclusions and the corrosion of the metallic crucible, the cooling fluid maintained at the second desired temperature range is arranged to flow within the plurality of passageways disposed within metallic crucible to cause at least a portion of the electrically conductive melt to be solidified on the inner wall surface, on the bottom inner surface, or on a combination thereof, to form a layer so as to lengthen the lifespan of the metallic crucible during operation.

Cooling Fluid Types

Various kinds of cooling fluid may be used for circulation in the passageways or the hollow tube of FIG. 2. In general, a cooling fluid according to the present specification may be in liquid phase, gas phase or vapor phase, and is introduced to flow within the plurality of passageways within the body of the metallic crucible at a temperature range to cause the metallic crucible to be within said first pre-determined temperature range. In one aspect, the cooling fluid is used to keep the hottest regions of the crucible surface below the creeping temperature of the crucible material. In a further aspect, the cooling fluid is used to produce a layer of solidified molten material on the inner crucible surface for protecting the inner crucible surface.

In a still further embodiment, the cooling fluid is mixed with additives such as propylene glycol, ethylene glycol, glycerol, sodium silicate, disodium phosphate, sodium molybdate, sodium borate, and dextrin or mixtures thereof. In yet another embodiment, the cooling fluid is mixed with inhibitors such as silicates and phosphates to mitigate any corrosive effects of the cooling fluid with the inner surface of the plurality of passageways.

In a specific embodiment, the cooling fluid is provided by a dielectric fluid such as those used as “transformer oil”. Such dielectric fluids are non-flammable and electrically insulating. The dielectric fluid is particularly suitably for the embodiment of FIG. 5. In a further embodiment, which is suitable for cooling with very low temperatures, such as −37 degrees, the oil is mixed with suitable additives to lower down a pour point of the oil to below −37 degrees. Typically, a lowering of the pour point to 10 degrees below the lowest temperature of the cooling fluid is sufficient to ensure an acceptable viscosity.

In another embodiment of the present specification, the cooling fluid is de-ionized water—to minimize scaling effects between the cooling fluid and the interior surface of the cooling conduit passageways—and in another embodiment the cooling fluid is a hydrocarbon cooling fluid such as mineral oil for having a higher fluid viscosity and therefore a desired range of thermal cooling properties during operation of the present invention, or mixtures and derivatives of the aforementioned cooling fluids.

In one embodiment, the cooling fluid is controlled within a second pre-determined temperature range of between 3 degrees Celsius to 110 degrees Celsius.

In another embodiment, cooling fluid is controlled within a second pre-determined temperature range of between 5 degrees Celsius to 55 degrees Celsius. In yet another embodiment, the cooling fluid is controlled within a second pre-determined temperature range between −37 degrees Celsius and 35 degrees Celsius. In another embodiment, which is suitable for a cooling fluid temperature range between 3 and 110 degrees Celsius, water is used as a cooling fluid, among other reasons for maintaining the material strength of the crucible and to eliminate or minimize material fatigue during prelonged operation, and for maintaining a layer of semi-solidified melt at the interior wall surface of the crucible, thereby having a protective layer to increase overall lifespan of the crucible during prelonged operation.

In one embodiment, the temperature range is adjusted to achieve a pre-determined thickness of a solidified layer of molten material at an inner wall of the crucible. the thickness can be between the range of 0.1 mm to 3 inches, depending on the size of the crucible and desired operation parameters during operating of the present invention. While a low temperature of the cooling fluid leads to a thicker protective coating on the crucible, a higher temperature of the cooling fluid interferes less with the inductive heating of the melt.

The cooling fluid exits from the plurality of passageways and flows away from the metallic crucible at a higher temperature, and is directed towards a remote site comprising a cooling fluid cooler device to reduce the temperature of the cooling fluid to within said second pre-determined temperature range prior to re-circulation back into the inlet of plurality of passageway.

The cooling fluid cooler device in one embodiment of the present specification is a closed loop evaporative-type cooling unit. This provides a cost saving and efficient cooling because the cooling fluid can be recycled. In another embodiment, the cooler device comprises a fluid chiller unit to return the heated cooling fluid exiting from the metallic crucible to a pre-determined temperature range prior to re-circulation back into the fluid path inlet and into the hollow passageways in operational communication with the metallic crucible.

In another non-limiting example, the cooling fluid is flowing and circulating to contact the exterior wall surface and exterior bottom surface of the metallic crucible at a fluid flow pressure, velocity and flow rate to control the temperature of the metallic crucible to be lower than the pre-determined temperature range of the melt disposed within the hollow interior region of metallic crucible.

To this end, the fluid flow pressure, velocity and flow rate of the cooling fluid is controlled by a remote processor, which is not shown in FIG. 5. In one specific embodiment, the processor is in remote communication with one or more sensors placed within or in proximity to the metallic crucible, the melt, or both. A non-limiting example of such evaporative coolers is disclosed in the publication “Analysis of Standards Options For Evaporative Coolers”.

In another embodiment of the present specification, the cooling fluid cooler device comprises a heat exchanger (either closed loop or open loop) that transfers heat gained from the heated cooling fluid exiting from the metallic crucible's hollow passageways or hollow conduits to the heat exchanger's heat sink such as running seawater, water, a forced fan circulation radiator, or derivatives of the evaporative cooling system previously described.

In another non-limiting reference example, the cooling fluid is chilled using a water chiller system such as one manufactured by Donaldson “AirCel” Process Water Chillers (Ultracool Series).

A gasifier 10, 10′ according to the present specification can be used to convert a carbon containing feed fuel and produce syngas according to one of the processes mentioned below.

According to the present specification, a carbon containing feed material is introduced into fluid contact with at least a portion of the melt 90, some of the feed material will be converted into synthesis gas (syngas), some carbon contained within feed material will be dissolved within the melt 90, and non-organic parts of the feed may further form a layer of molten slag 100 that resides above the surface level of melt 90. In one embodiment, a slag drain 110 is arranged to allow for the slag 100 to be withdrawn either continuously or periodically.

The generalized flow path of the syngas is indicated by references 80, 81. In one embodiment, a syngas cooler device (not shown) is placed within the flow path 80, 81 or further downstream of flow path 80 to cool the gas temperature of the syngas to a pre-determined temperature range. In specific embodiments, a Syngas cooler device is provided by a steam generator device, or a heat exchanger device having a radiant heating coil, a convective heating coil, or combinations thereof (not shown).

In one embodiment, the feed material is introduced on a dry basis. In another embodiment, it is mixed with a liquid to form a slurry. In yet another embodiment, the feed material is reduced to a pre-determined sieve size range before being delivered into conduits, or formed into slurry prior to conversion into syngas.

In yet another embodiment, the feed material is crushed, shredded, milled to a pre-determined sieve size range, by deploying a variety of grinding, milling, shredder or crushing equipment, to which details and generalized references can be found in Chapter 20 of “Size Reduction and Size Enlargement”.

In a specific embodiment, the shredding equipment is manufactured by Cumberland, CMS Medium Duty single shaft shredder model CMS 850, 1200, 1500, 2000 (Part Number ESS-0039-C), or by SSI Shredding Systems Inc. (non-limiting example of a Quad Model Q55, Q160, among others available).

One or more flow path device are configured to be in communication with the metallic crucible to form a substantially gas-tight assembly so as to allow for syngas to flow from metallic crucible to a flow path device.

In one embodiment, one or more cooling units are arranged within one or more flow path device to cause cooling of the syngas to a pre-determined temperature range. In a specific embodiment, the cooling units are provided by a tubular-type steam generator device to cause exchange of heat from the syngas flowing within the flow path device to the water introduced into the steam generator device to convert the water into steam.

General Process Description of the Molten Metal Gasifier

A process for the generation of syngas by partial oxidation, pyrolysis, gasification, or in combination, of a multiplicity of feed fuels, wherein at least a portion of syngas is converted to electrical power, mechanical shaft power, one or more Fischer-Tropsch products, carbon dioxide, hydrogen, derivatives thereof, or combinations thereof, comprising:

(1) reacting the multiplicity of feed fuels with an oxygen-containing gas and a melt in a reactor to produce syngas, reactor substantially made of a metallic material, a metal alloy, or in combination, (2) controlling the temperature of at least the inner surface of the reactor by cooling at least a portion of the reactor with a coolant fluid circulating within a closed loop fluid circulation circuit, wherein the coolant fluid is introduced into the closed loop fluid circulation circuit at a pre-determined temperature range of between −37 degrees Celsius to 110 degrees Celsius, among other reasons to maintain the material strength of the crucible and to eliminate or minimize material fatigue during prelonged operation. and to maintain a layer of semi-solidified melt at the interior wall surface of the crucible, thereby having a protective layer to increase overall lifespan of the crucible during prelonged operation. (3) heating the melt towards a pre-determined melt temperature range of between 800 degrees Celsius to 2,000 degrees Celsius. As feed fuel is introduced at a desired flow rate into the melt, the temperature of the melt will be lowered to its optimal temperature range that can be between the range of 500 degrees c to 1800 degrees c.

It should be noted that step (3) of the process can be realized by placing the induction coil of the induction heater within proximity of the metallic crucible and providing it with a power control signal to regulate and control the parameter of the power supply circuit so as to cause the induction coil to generate a pre-determined heating power to be transferred into the melt. The heating power is controlled towards the pre-determined melt temperature range, for example, to heat the melt towards a target of 2000 degrees Celsius.

As feed fuel is introduced at a desired flow rate into the melt, the temperature of the melt will be lowered to its optimal temperature range that can be between the range of 500 degrees c to 1800 degrees c.

In another embodiment of the specification, the power control signal causes the induction coil to generate a pre-determined heating power to be transferred into the melt, at the pre-determined melt temperature range, for example, to heat the melt to within a range of 1400 to 1600 degrees Celsius. in another embodiment of the present invention, the melt is heated and melted towards a desired temperature range using one or more electrically powered resistive heating elements in fluid contact with one or more identified portions of the melt.

in another embodiment of the present invention, the melt is heated and melted towards a desired temperature range using one or more electrically powered resistive heating elements in proximity to one or more identified portions of the melt.

In one embodiment, the feed fuel of the abovementioned processes comprises one or more carbon-based and/or carbon-containing materials which may be solid, liquid, gas, or any combination thereof. The feed fuel can include, but is not limited to, biomass (i.e., plant and/or animal matter or plant and/or animal derived matter); coal (including anthracite, bituminous, sub-bituminous and lignite); rubber-derived materials; oil shale; coke; tar; asphaltenes; landfill waste derived material; sewage derived material; flue gas exhaust, low-BTU gas, engine exhaust gas, incinerator exhaust gas, combustion burner equipped boiler exhaust gas, low ash or no ash polymers; hydrocarbon-based polymeric materials; biomass derived material; or by-product derived from manufacturing operations.

Feed fuel materials or feedstocks, can also be provided by agricultural feedstocks, forestry-based feedstocks, municipal solid waste (MSW), MSW can include the following: selected from the group consisting of waste plastics, used tires, paper, scrap-wood, food-processing waste, sewage, sludge, green-waste.

The feed fuel material or feedstocks according to the present specification may comprise, among others,

-   -   fossil materials such as crude oil, tar sands, shale oil, coal,         natural gas, and combinations thereof, as well as     -   coal mine tailings, coal waste, coal fines, coal-water slurry,         coal-liquid mixtures, and combinations thereof or also     -   a refinery residual material that comprises low-value         carbonaceous by-products such as asphaltenes, tars and         combinations thereof.

The hydrocarbon-based polymeric materials can include, but are not limited to, thermoplastics, elastomers, rubbers, including polypropylenes, polyethylenes, polystyrenes, including other polyolefins, homo polymers, copolymers, block copolymers, and blends thereof, PET (polyethylene terephthalate), poly blends, poly-hydrocarbons containing oxygen; heavy hydrocarbon sludge and bottoms products from petroleum refineries and petrochemical plants such as hydrocarbon waxes, blends thereof, derivatives thereof, and combinations thereof. In one or more embodiments, the feed fuel can include one or more of the above listed materials. Accordingly, the process can be useful for accommodating mandates for proper disposal of previously manufactured materials.

In at least one specific embodiment the feed fuel can be suspended, slurried or otherwise conveyed by the carrier fluid and gasified in the gasification zone within the molten material disposed within metallic crucible of the present specification to provide a syngas containing hydrogen, carbon monoxide, and carbon dioxide.

Various contact, or contactless sensors are placed and arranged in suitable positions in proximity to the metallic crucible, the melt, the freeboard space above the liquid surface of the melt, portions where the evolving syngas is generated from the melt, or in combination, so as to allow for the monitoring, recording and control of the pre-determined power control signal. According to the present specification, various process pumps, motors and actuators, such as gas compressors, valve control devices, electrical and electronic switches, relays, pressure control regulators and valve devices are further in operational communication with one or more processor and one or more control parameter signals. These include but are not limited to prime moving devices of the shredders, conduit flow pumps, gas compressors, electric motor drives, hydraulic and or pneumatic actuators, etc.

In one embodiment, the metallic crucible 40 is formed by machining a metal block piece, or sintered into its crucible form using one or more metal powder, such as tungsten powder.

In another embodiment of the present specification, the metallic crucible can be formed by casting liquid metal or partially liquid metal into a mold. The metallurgical casting steps may comprise centrifugal casting, or other suitable methods for liquid metal casting into a determined mold, or combinations of those methods.

In yet another embodiment, the metallic crucible 40 is fabricated by pouring a pre-determined liquid metal or alloy into a mold to be casted into the shape and geometry of the metallic crucible and cooled to be solidified, wherein the plurality of passageways within the body of the metallic crucible is also formed from the arrangement of the mold or molds. In another embodiment, the metallic crucible is formed by having a cylindrical pipe section having a pre-determined wall thickness and metal or metal alloy composition to be welded at one of its end with a bottom floor.

In another embodiment of the present specification, the metallic crucible 40 is forged using a number of metallurgical forging steps. In one embodiment of the present specification, the metallic crucible is formed out of ferritic stainless steel. In another embodiment of the present specification, the metallic crucible comprises steel with varying amounts of carbon, silicon, manganese, chromium, aluminum, nickel or a combination thereof. In another embodiment of the present specification, the metallic crucible is substantially made of a homogenous metal such as steel, tungsten, etc.

Examples for such metal casting techniques are provided in the document “Feeding and Risering”.

Other generalized publications on metal and metal alloy casting can be found in: “Metal Casting—A General Review”. Manufacturing of pipes having a cylindrical geometry may be implemented by machines made by manufacturers such as the reference “Tulsa Centrifugal catalogue”.

In another embodiment, the metallic crucible 40 is sintered with a metal powder into its pre-determined geometry and form.

FIG. 3 shows across section partial view of electrically insulating material 220 which can be interposed between the metallic crucible 40 and the induction coil 120. One or more insulating materials 220 are interposed between the outer surface of the metallic crucible 40 and an induction coil 120 to cause electrical insulation and isolation between the metallic crucible 40 and the induction coil 120. The layer 220 of insulating material, which is interposed between one or more induction coil 120 surrounding the metallic crucible 40, prevents an electrical short-circuit between one or more induction coil 120 that surrounds the metallic crucible 40. The insulating layer of material 220 may comprise, among others, alumina, mica, or one or more refractory materials.

The insulating material 220 has a maximum continuous service temperature of at least 1200 degrees Celsius (1200 degrees C.) and is at least 1 millimeter in thickness. It should be noted that maximum continuous service temperature means the insulating material 220 can withstand at least this temperature without degradation in heat and or electrical insulation performance for a period of longer than 30 days or beyond. The induction coil 120 is part of the induction coil apparatus 120 shown in FIG. 1.

In another embodiment of the present specification, the insulating material 220 is at least 10 millimeters in material thickness, and in yet another embodiment of the present specification, the insulating material 220 is formed to a predetermined total thickness by a multiplicity of similar sheets of said insulating material 220 combined together in a multiple sheet arrangement.

In one embodiment, the insulating material comprises alumina sheet, in another embodiment, it is made of a refractory material that is electrically non-conductive. The insulating material 220 is interposed between the induction coil 120 and the metallic crucible 40. The proximate distance between the metallic crucible 40 and induction coil depends on the size and design of the gasifier 40.

In another embodiment, an induction coil 120 is provided close to the bottom of the metallic crucible 40 and the insulating layer of material is interposed between the outer wall surface and the outer bottom wall surface of the metallic crucible 40 and the induction coil (or induction coils).

In one embodiment, a proximate distance d between the metallic crucible 40 and induction coil 120 ranges between 1 millimeter to 3 inches (76.2 mm). In another embodiment, the proximate distance d between the metallic crucible 40 and induction coil 120 ranges between 10 millimeters to 20 inches (508 mm). In a third embodiment, the proximate distance d between the outer wall surface of the metallic crucible 40 and the inner wall surface of induction coil 120 ranges between 5 millimeters to 60 inches (1524 mm).

In yet another embodiment of the present specification, the insulating material 220 comprises an electrically insulating material having with a density or porosity within a specified range in order to provide the insulating material 220 with a pre-determined range of thermal conductivity.

In one embodiment, the height of the insulating layer of material is configured to be at least the total height of the metallic crucible. In another embodiment the height of the insulating layer of the material is configured to be greater than the total height of the metallic crucible and adapted in a manner where at least a portion of the insulating material provides excess insulating material interposed between the induction coil (or induction coils) and the outer surface of the metallic crucible.

In an embodiment not shown here, an electrical resistance heating coil replaces the induction coil 120 of the embodiment of FIGS. 1 and 2 to form new embodiments. All variations described above can be applied, and the electrical resistance heating coil is brought into close thermal contact with the crucible 40. Thermally conductive material can be provided in the vicinity of the electrical resistance heating coil in order to improve heat transfer to the crucible 40.

In another embodiment not shown here, one or more electrical resistance coils are provided inside the hollow which is defined by the crucible 40, in order to bring the electrical resistance heating coil in close contact with the melt 90 and molten slag 100. Such electrical resistance coils can be provided together with one or more inductive coils and—in a further embodiment—also together with both an electrical resistance heating coiled and with one or more inductive coils. Cooling as described above with reference to FIG. 2 enhances the durability of the crucible 40.

in one embodiment the one or more electric resistance heating element is configured to generate heat when powered with a desired voltage of either alternating current or direct current, to cause heating and melting of the electrically conductive charge material resident within the hollow of the metallic crucible so as to cause formation of a melt (molten form of the melted electrically conductive charge material).

in another embodiment the one or more electric resistance heating element is configured to generate heat when powered with a desired voltage of either alternating current or direct current to maintain melting of the melt and one or more electric resistance heating element is in fluid contact with one or more portions of the melt.

it is known that the electric resistance element can dissipate close to 100 percent of all its electrical energy into thermal heat to cause melting of the melt, while inductive melting of the melt using one or more induction heating apparatus can provide both melting and stirring of the melt during operation.

in another embodiment the melt is heated, melted using a combination of electric resistive heating and inductive heating depending on one or more desired operating parameter stored in a remote processor in operational communication with the metallic crucible, the feeder conduit device, the gas exhaust conduit, or a combination thereof.

FIG. 4 shows a second embodiment of an insulated coil that surrounds a crucible 40 in which an insulation material 220 surrounds the induction coil 120 in the form of an insulation jacket 221. A distance d is provided between an outer surface of the insulation jacket 221 that is adjacent to the crucible 40 and an outer surface of the crucible. A circulating cooling fluid 146 is provided in a region around the crucible and around the induction coil 120.

FIG. 5 shows a cross-sectional view of a further embodiment of a device for converting feed fuel to synthesis gas. According to this embodiment, the metallic crucible 40 is suspended within an encasement tank or housing 142 that is filled with a dielectric fluid 143, which is also referred to as “dielectric coolant”. The dielectric fluid 143 is circulated through the encasement tank 142 through a cooling fluid inlet 144 and a cooling fluid outlet 145.

An induction coil 201 is provided within the outer container 142 in proximity to the metallic crucible 40. In FIG. 5, a distance d between the induction coil 120 and an outer surface of the metallic crucible is indicated. A slag conduit 110 passes from the interior of the crucible 40 to the exterior of the outer container without passing through the interior of the outer container 142.

The dielectric cooling fluid 143 provides cooling for the crucible 40 and the induction coil 120. According to the embodiment of FIG. 5, an insulating material is not required but it may be provided in addition to the dielectric cooling fluid 143.

In the embodiment of FIG. 5, the metallic crucible 40 is substantially made of a metallic material and substantially solid in construction without having passageways provided within the body of the crucible, as in above described Figures. If desired, such passageways may also be provided to further enhance the cooling effect. In one embodiment, the metallic crucible is made in one piece.

In a further embodiment, the metallic crucible 40 is provided with a flange or metallic material that radially extends toward the exterior to improve heat dissipation. The flange or extended metallic material is either made in one piece with the crucible or attached to the top circumference rim region of the crucible.

The metallic crucible 40 is attached to the encasement tank 142 in a manner that the interior free bulk space within the encasement tank or housing surrounds the exterior wall surface of the metallic crucible 40 and the exterior bottom surface of the metallic crucible 40. Thus the encasement tank 142 and the metallic crucible 40 are attached to form a closed interior free bulk space within the encasement tank 142 that surrounds the exterior wall surface and exterior bottom surface of the metallic crucible 40.

The coolant fluid 143 flows and circulates within the closed interior free bulk space of the encasement tank 142 to regulate the temperature of the crucible 40. In one embodiment, the cooling fluid 143 is introduced into the encasement tank 142 and fluidly contacts the metallic crucible's 40 outer surface to cause at least a portion of the crucible 40 to be cooled. In one embodiment, the cooling of the crucible 40 is controlled to a predefined temperature range such that at least a portion of an electrically conductive melt disposed within the crucible 40 forms a layer of partially solid or solid material within at least a portion of the inner wall surface, bottom inner surface, or a combination of the metallic crucible's 40 inner surfaces. Thereby, the lifespan of the metallic crucible 40 is increased by reducing occurrences of inclusions and corrosion of the metallic crucible 40.

A heating device such as an induction coil 120 is placed in proximity to the metallic crucible 40 to cause melting and heating of a melt disposed within the hollow region of the crucible 40. The induction coil 120 is placed within the closed interior free bulk space within encasement tank 142.

FIG. 6 shows an enlarged portion of the gasifier of FIG. 5, in which the induction coil 120 that surrounds the crucible 40 is shown in a cross sectional view.

According to the embodiment of FIG. 5, the induction coil 120 is designed as a hollow coil 120 which is surrounded by an insulation jacket 221. By providing the induction coil 120 as a hollow coil, the surface of the coil increases. Thereby, the amount of electric current through the coil can be increased, if the alternating current frequency is chosen to be in a range in which a skin effect limits the bulk current. According to a first embodiment, a distance d between the insulation jacket and an outer wall of the crucible 40 is chosen in the range from 0.5 to 30 inches (12.7 mm to 762 mm). According to another embodiment, the distance d is chosen in the range from 0.5 to 60 inches (12.7 mm to 1524 mm).

In an embodiment not shown here, an electrical resistance heating coil replaces the induction coil 120 of the embodiment of FIGS. 5 and 6 to form additional embodiments. All variations described above can be applied, and the electrical resistance heating coil is brought into close thermal contact with the crucible 40. Thermally conductive material can be provided in the vicinity of the electrical resistance heating coil in order to improve heat transfer to the crucible 40.

In another embodiment not shown here, one or more electrical resistance coils are provided inside the hollow which is defined by the crucible 40, in order to bring the electrical resistance heating coil in close contact with the melt 90 and molten slag 100. Such electrical resistance coils can be provided together with one or more inductive coils 120 and—in a further embodiment—also together with both an electrical resistance heating coil and with one or more inductive coils 120. Cooling as described above with reference to FIG. 5 enhances the durability of the crucible 40.

The present specification discloses, among others, a device, also referred to as a gasifier, for converting one or more feed fuel to syngas. One example of such a device is provided by the gasifier 10 of FIG. 1. The device comprises a metallic crucible for holding an electrically conductive material, such as the crucible 40 of FIG. 1, which is shown in greater detail in FIG. 2.

The gasifier comprises a feeding conduit, such as the overhead lance 52 or the feed conduits 50, 51 of FIG. 1, for providing a flow stream of the one or more feed fuel to be delivered into contact with the molten material to convert at least a portion of one or more feed fuel to syngas.

At least one supply conduit, such as the downstream application conduit 140 of FIG. 1, is provided for delivering the syngas to the exterior of the crucible.

Furthermore, the device comprises at least one electric heater in the vicinity of the crucible, e.g. with an induction coil for providing a flow of current through the at least one electric induction heater, such as the induction coil 120 shown in FIGS. 1, 3 and 4. The electric induction heater is provided such that an alternating field of the electric induction heater causes an alternating field within the crucible which in turn causes melting and inductive heating of the electrically conductive material to form a molten material disposed within the metallic crucible. For effective inductive heating, the electrically conductive material may comprise a ferromagnetic substance such as iron, cobalt, nickel, alloys thereof, chromium dioxide, europium oxide, Heusler alloys or others.

The electric heater can—inside or outside of the metallic crucible—also comprise an electric resistance heater, replacing the induction coil 120 or as an add-on to inductive heating.

Moreover, the device comprises a liquid cooling arrangement for the crucible, such as the hollow passageways 211, 214, the hollow conduit 310 of FIG. 2 or the outer container of 142 of FIG. 5. According to one embodiment, the liquid cooling arrangement comprises hollow passageways, which are provided within the body of the crucible, such as the first and second cooling arrangement of FIG. 2. In particular, the hollow passageways of the liquid cooling arrangement may be provided in a side wall of the crucible, as in the first cooling arrangement of FIG. 2, or in a bottom wall of the crucible.

According to a further embodiment, the liquid cooling arrangement comprises hollow conduits, which surround an outer surface of the crucible, such as the hollow conduits 310 of FIG. 2. In particular, the hollow conduits may be arranged in a series of turns or in large sections around the crucible.

According to a further embodiment, the liquid cooling arrangement comprises a hollow conduit between the crucible and an outer container which surrounds at least a part of the crucible. In particular, the hollow conduit may be formed by an intermediate region between the outer container and the crucible or the shell of the crucible, such as in the embodiment of FIG. 5. In particular, the induction coil may be placed in a region of circulating cooling liquid within the container, such as in FIG. 5. Thereby, a separate cooling arrangement for the induction coil can be avoided.

In one embodiment, the outer container surrounds the crucible along the bottom of the crucible and along the side walls of the crucible up to at least half of the crucible's height. In another embodiment, the outer container surrounds the crucible along the bottom of the crucible and along the side walls of the crucible up to at least half or up to at least two thirds of the crucible's height.

For the removal of slag, a slag channel, such as the slag channel 110 of FIG. 5, is provided between a side wall of the crucible towards the exterior of the crucible.

In the embodiment of FIG. 5, which comprises a hollow conduit for circulating cooling fluid, the slag channel is provided such that it does not pass through the hollow conduit, or at least not through the portion of the hollow conduit which is provided for transporting the cooling liquid. Furthermore, the crucible may be provided with a tilting mechanism to improve the removal of slag through the slag channel.

According to further embodiments of the present specification, various arrangements may be provided to insulate the induction coil thermally or electrically against the crucible and/or against the cooling fluid. According to a first embodiment, the induction coil is surrounded by an insulating material, such as shown in FIG. 4 or FIG. 6. According to another embodiment, which is shown in FIG. 3, a layer of insulating material is provided between the induction coil and the crucible.

In particular, the induction coil may be provided within a distance of 1 mm to 1.52 m to the side walls of the crucible. In a first embodiment, the distance is between 1 mm and 3 inches (76.2 mm), in a second embodiment, the distance is between 10 mm and 20 inches (508 mm) and in a third embodiment, the distance is between 5 mm; 60 inches (1524 mm). In another embodiment, the induction coil is provided as a hollow coil. Inductive coils can be provided as hollow coiled, especially when the feeding frequency of the inductive heating is chosen such that the inductive currents appear as skin currents due to skin effects.

An electric resistance coil may be provided within a distance of 0 mm to 1.52 m to the side walls of the crucible, both from the hollow inside or from the outside of the crucible. Electric resistance coils can be provided as solid, non-hollow coils, in order to promote the conversion of electricity to heat.

According to another description of the embodiments of the present specification, the present specification discloses a device, which is also known as a gasifier, with a substantially metallic crucible which encloses a hollow with a metallic surface for holding a metallic material in the hollow. The hollow corresponds to an interior space that is defined by a bottom inner surface of the crucible wall and by lateral inner surfaces of the crucible. The substantially metallic crucible may be provided by a metallic crucible, but also by a crucible comprising a refractory material component and having a metallic inner surface.

At least one heater that is adapted to provide heating to the crucible and, during operation, to its content is disposed in proximity to the metallic crucible. The heater may comprise an electrical coil, e.g. an induction coil as mentioned above. In other embodiments, the heater comprises an electric resistor, such as a heating coil, or a combustion heater.

A fluid cooling arrangement is disposed in proximity to the metallic crucible. Herein, the term “fluid” may refer to one or more liquid components, one or more gaseous components or any mixture thereof. In particular with reference to water a liquid-gas mixture is also referred to as “wet steam” and the gaseous phase as “dry steam”. In one embodiment, the fluid cooling arrangement comprises means to move the gaseous components, such as blower, and means to contain the gaseous components, such as a sealing gasket.

A feeding conduit, such as the overhead lance conduit 52 or the feeding conduits 50 and 51, extends between the outside of the crucible and the inside of the crucible. At least one supply conduit, such as the downstream application conduit 140 of FIG. 1, is provided between the inside of the crucible and the outside of the crucible.

A further embodiment discloses, among others, a device, which is also known as a gasifier, with a holder unit, such as a metallic crucible, with a metallic surface that defines a hollow for holding a molten metallic material. In contrast to other embodiments, a body of the holder unit may also be made completely or partially of a non-metallic material such as a ceramic material, a refractory material or others.

At least one heater unit is disposed in proximity to the holder for heating the hollow. Similarly to the previously mentioned heater, the heater unit may comprise an electrical induction coil, as mentioned above. In other embodiments, the heater comprises an electric resistor such as a heating coil or a combustion heater.

The device comprises a feeder unit for providing a flow stream of one or more combustible material to be delivered into the hollow. Examples of feeder units are provided by the feeding conduits of FIG. 1. Further examples comprise, but are not limited to, portholes, conveyor belts, a circulating row of containers, blowers, injectors, dispersion nozzles and similar devices.

A cooler unit for cooling the holder is disposed in proximity to the holder. By way of example, a cooler unit may be provided by conduits for circulating a cooling fluid or liquid, by an outer container which comprises a cooling fluid or liquid or by heat conducting parts such as cooling fins, or a combination thereof.

At least one supply means, such as a downstream application conduit, is provided for delivering a gas from inside the crucible to the outside of the crucible and for supplying the gas to a further apparatus such as a burner or a processing plant or to a storage tank.

According to a further aspect of the present specification, a gasification method for converting one or more feed fuel to syngas is disclosed. An electrically conductive material, such as a metal or a metallic salt, is placed within a metallic crucible, for example in one the crucibles shown in FIG. 1, 2, 5 or 11. The electrically conductive material is heated to form a molten material disposed within the metallic crucible, such as the molten metal layer 90 and the slag layer 100 of FIG. 1. The molten material is maintained in a molten state, for example by heating the molten material.

At least a portion of the crucible, such as for example a metallic inner surface, is cooled with a cooling liquid. In some embodiments, the cooling temperature is adjusted such that the molten metal forms a “frozen” protective layer on the crucible wall or on the metallic surface of the hollow.

A flow stream of the one or more feed fuel is delivered into contact with the molten material, thereby converting at least a portion of the one or more feed fuel to syngas. The syngas is extracted from the crucible. The flow stream of feed fuel may be provided as a liquid stream, as a stream of solid components, as a gaseous stream with finely dispersed solid components, a gas stream or also as a combination thereof.

In particular, the cooling of the crucible may comprise the cooling of the body of the crucible from inside the body of the crucible, for example by way of inner passageways, such as shown in FIG. 2, or it may comprise the cooling of the outer surface of the crucible from outside the crucible, for example by way of outer passageways, such as shown in FIG. 2.

According to more specific embodiments, an input temperature, an output temperature or an intermediate temperature of the cooling liquid is controlled to lie within a predetermined temperature range, for example between −37 to 35° C., between 5 to 55° C., or between 3 to 110° C.

According to a further embodiment, the cooling of the crucible comprises circulating the cooling liquid, whereby at least a portion of the cooling liquid is reused. According to further embodiments, the circulating of the liquid comprises the phases of evaporating the liquid, condensing the evaporated fluid and recirculating the condensed liquid to the crucible. In particular, the circulating of the liquid may comprise phases of evaporating the liquid, for example by evaporation in a cooling tower or by evaporation in a low pressure environment, condensing the evaporated fluid and recirculating the condensed liquid to the crucible.

According to a further embodiment, a gasification method comprises placing a metallic material within a hollow, for example an interior region of a crucible, such that it is in contact with a metallic surface of the hollow, such as an interior surface of a crucible. The metallic material is melted to form a molten metallic material and the molten metallic material is maintained in a molten state by supplying heat, for example by inductive heating, by heat conduction or by other means. In particular, the crucible may be provided by one of the crucibles shown in FIG. 1, 2 or 5. According to the present embodiment, a body of the crucible which provides the hollow may also entirely or partially be made from a non-metallic material.

The metallic surface of the hollow is cooled with a cooling fluid. The fluid may comprise a liquid such as water or transformer oil or others or it may also comprise one or more gaseous components.

One or more flow streams of one or more hydrocarbon-containing material are brought into contact with the molten metallic material, for example by delivering them through a conduit which is directed towards the molten metallic material, such as for example the overhead lance 52 of FIG. 1.

Reaction gas is extracted from the hollow, for example by providing a conduit in a cover that provides an upper boundary to the hollow. The reaction gas may comprise syngas but also other components.

The hydrocarbon-containing material is a form of feed fuel and may comprise materials such as carbon, rubber, wood pellets or other fuels mentioned in the specification. In particular, the reaction gas may comprise syngas.

According to the application, at least a portion of the syngas can be used to produce electrical power, hydrogen, and/or commodity chemicals such as Fischer-Tropsch (“F-T”) products, hydrogen, carbon monoxide and/or carbon dioxide. FIGS. 7 to 10 show some examples of chemical processing plants or reactors which can be used to further process the syngas. Further examples of chemical processing plants are provided below.

Fischer-Tropsch (“F-T”) products, include refinery/petrochemical feedstocks, transportation fuels, synthetic crude oil, liquid fuels, lubricants, alpha olefins, waxes, and the like. The F-T reaction can be carried out in any type reactor of, for example, through the use of fixed beds; moving beds; fluidized beds; slurries; bubbling beds, or any combination thereof. The F-T reaction can employ one or more catalysts including, but not limited to, copper-based, ruthenium-based; iron-based; cobalt-based; mixtures thereof, or any combination thereof. The F-T reaction can be carried out at temperatures ranging from about 190° C. (374° F.) to about 450° C. (842° F.) depending on the reactor configuration. Additional reaction and catalyst details can be found in U.S. 2005/0284797 and U.S. Pat. Nos. 5,621,155; 6,682,711; 6,331,575; 6,313,062; 6,284, 807; 6,136,868; 4,568663; 4,663,305; 5,348,982; 6,319,960; 6,124,367; 6,087,405; 5,945,459; 4,992,406; 6,117,814; 5,545,674, and 6,300,268.

Fischer-Tropsch products include liquids which can be further reacted and/or upgraded to a variety of finished hydrocarbon products. Certain products, e.g. C4-C5 hydrocarbons, can include high quality paraffin solvents which, if desired, can be hydrotreated to remove olefinic impurities, or employed without hydrotreating to produce a wide variety of wax products. Liquid hydrocarbon products, containing C16 and higher hydrocarbons can be upgraded by various hydroconversion reactions, for example, hydrocracking, hydroisomerization, catalytic dewaxing, isodewaxing, or combinations thereof. The converted C16 and higher hydrocarbons can be used in the production of mid-distillates, diesel fuel, jet fuel, isoparaffinic solvents, lubricants, drilling oils suitable for use in drilling muds, technical and medicinal grade white oil, chemical raw materials, and various hydrocarbon specialty products.

Commodity chemicals include, but are not limited to, acetic acid, phosgene, isocyanates, formic acid, propionic acid, mixtures thereof, derivatives thereof, and/or combinations thereof, ammonia, using the Haber-Bosch process described in LeBlanc et al in “Ammonia,” Kirk-Othmer Encyclopedia of Chemical Technology, Volume 2, 3rd Edition, 1978, pp., 494-500. In one or more embodiments, synthesis gas, or commodity chemicals or F-T products or a combination thereof can be used for the production of alkyl-formates, for example, the production of methyl formate. Any of several alkyl-formate production processes can be used, for example a gas or liquid phase reaction between carbon monoxide and methanol occurring in the presence of an alkaline, or alkaline earth metal methoxide catalyst. Additional details can be found in U.S. Pat. Nos. 3,716,619; 3,816,513; and 4,216,339.

In one or more embodiments, a reaction device can be used to produce methanol, dimethyl ether, ammonia, acetic anhydride, acetic acid, methyl acetate, acetate esters, vinyl acetate and polymers, ketenes, formaldehyde, dimethyl ether, olefins, derivatives thereof, or combinations thereof. For methanol production, for example, the Liquid Phase Methanol Process can be used (LPMEOH™). In this process, at least a portion of the carbon monoxide in the syngas can be directly converted into methanol using a slurry bubble column reactor and catalyst in an inert hydrocarbon oil reaction medium. The inert hydrocarbon oil reaction medium can conserve heat of reaction while idling during off-peak periods for a substantial amount of time while maintaining good catalyst activity.

Additional details can be found in U.S. 2006/0149423 and in the prior published document “Liquid Phase Methanol (LPMEOH™) Project Operational Experience”. Gas phase processes for producing methanol can also be used. For example, known processes using copper based catalysts, the Imperial Chemical Industries process, the Lurgi process and the Mitsubishi process can be used.

In one or more embodiments, the hydrogen-rich product can be used in one or more downstream operations, including, but not limited to, hydrogenation processes, fuel cell energy processes, ammonia production, and/or hydrogen fuel. For example, the hydrogen-rich product can be used to make hydrogen fuel using one or more hydrogen fuel cells. In one or more embodiments, at least a portion of the syngas can be combined with one or more oxidants and combusted in one or more combustors to provide a high pressure/high temperature exhaust gas.

The high pressure/high temperature exhaust gas can be passed through one or more turbines and/or heat recovery devices to provide mechanical power, electrical power and/or steam. In one or more embodiments, the exhaust gas can be introduced to one or more gas turbines to provide an exhaust gas and mechanical shaft power to drive the one or more electric generators. In one or more embodiments, the exhaust gas can be introduced to one or more heat recovery systems to provide steam. In one or more embodiments, a first portion of the steam can be introduced to one or more steam turbines to provide mechanical shaft power to drive one or more electric generators. In one or more embodiments, a second portion of the steam can be introduced to the gasifier, and/or other auxiliary process equipment. In one or more embodiments, lower pressure steam from the one or more steam turbines can be recycled to the one or more heat recovery systems. In one or more embodiments, residual heat can be rejected to a condensation system well known to those skilled in the art or sold to local industrial and/or commercial steam consumers.

In one or more embodiments, the heat recovery system can be a closed-loop heating system, e.g. a waste heat boiler, shell-tube heat exchanger, and the like, capable of exchanging heat between the exhaust gas and the lower pressure steam to produce steam. In one or more embodiments, the heat recovery system can provide up to 17,350 kPa (2,500 psig), 855° C. (1,570° F.) superheated steam without supplemental fuel.

FIGS. 7 and 8 show crude oil refinery plants 1000, 1000′ which are adapted for connection with a gasifier 10, such as shown in FIGS. 1 to 6.

According to the present specification, an oil refinery plant 1000, 1000′ is configured to be communicatively connected with one or more molten metal reactors, also known as gasifiers, which have a molten metal disposed therein.

For purposes of this specification and its various embodiments including the methods A and B, an oil refinery, crude oil refinery, hydrocarbon processing plant, petroleum processing plant or derivatives thereof are generalized examples of a system to refine a hydrocarbon process fluid such as crude oil, or partially refined or processed hydrocarbon product into one or more refined or “completed” hydrocarbon products.

A communicative connection between a crucible and a chemical processing plant, such as a hydrocracking or thermal distillation plant can be provided in various ways, for example by exchanging heat or other forms of energy like electric energy, by measuring and transmitting process parameters, by exchange materials and especially by transmitting reaction products from the crucible to the chemical processing plant or from the chemical processing plant to the crucible. The communication between the crucible and the chemical processing plant can lead to a better efficiency of the processes or to a better quality of the reaction products, for example.

The oil refineries 1000, 1000′ comprise a vacuum distillation unit 1200, which is also referred to as vacuum distillation column, and an atmospheric distillation unit 1201, which is also referred to as atmospheric distillation column. While in the oil refinery 1000 of FIG. 7 an inlet of the vacuum distillation plant 1200 is connected to an outlet of an atmospheric distillation column 1201, the vacuum distillation plant 1200 of the oil refinery 100′ of FIG. 7 is connected to a separate supply of reduced crude feedstock. The vacuum distillation plant 1200 is shown in more detail in FIG. 10.

According to the current specification, the heat of the gasifier 10 can be supplied to an oil distillation plant 1000, 1000′ in various ways such as: via a heat exchanger at the process heater 601 for cold preheating of crude oil before desalting, via a heat exchanger at the process heater 602 for hot preheating of crude oil after a desalting step, via a heat exchanger at the process heater 603 for heating up the crude oil to a final input temperature before supplying it to an atmospheric distillation stage, via a heat exchanger at the process heater 604 for preheating an input to the vacuum distillation plant 1200 and via a heat exchanger at the process heater 605 for heating up the input to the vacuum distillation plant 1200 to a specified input temperature.

A process heater according to the present specification refers to a device that is designed to generate heat or transfer heat from a source to be applied to the input hydrocarbon process fluid so as to cause thermal treatment, refining or processing of the input hydrocarbon process fluid into a finished product. The process heater may also be referred to as crude oil furnace, pre-heat train, heat exchanger, heat exchanger train, furnace, CO boiler, boiler or heat recovery unit, among others.

The oil refineries 1000, 1000′ are configured with one or more molten metal reactors, such as the one shown in FIGS. 1 to 6, each adapted with a metallic crucible 40 and surrounded with one or more induction coil and each having an electrically conductive material disposed within, one or more feed material is supplied into contact with electrically conductive material that is melted within each reactor to its molten form so as to cause formation of synthesis gas (syngas) that is subsequently combusted with an oxidant gas to generate heat which is further directed to heat exchangers 601-605 to heat crude oil or a process hydrocarbon fluid. In an embodiment not shown here, the crucible can partly or entirely be made of non-metallic material, such as concrete, ceramics, a refractory lining, fire clay, chamotte, fire bricks or a combination of these materials, including non-metallic and metallic materials in combination.

A generalized reference example of oil refining can be made to “A Simple Guide to Oil Refining” published by ExxonMobil Australia Pty Ltd ABN 48 091 561 198.

A generalized and non-limiting example of an oil refinery may be taken from U.S. Pat. No. 2,733,191, U.S. Pat. No. 2,338,595 (John W. Packie et al), U.S. Pat. No. 4,082,653, U.S. Pat. No. 3,537,985. Another example of an oil refinery plant that can be used together with the embodiments of the present specification is provided in the document “Available and Emerging Technologies for reducing Greenhouse Gas Emissions from the Petroleum Refining Industry”.

Examples for heat producing burners 601-606 are for example those produced by SAACKE GmbH called the SAACKE SSB-LCG, each having a 11 MW burner output, or heat producing burners manufactured by Aecometric Corporation (low energy gas burner).

Generally, the crude oil from which gasoline and other liquid hydrocarbon fuels are derived comprises a diverse mixture of hydrocarbons and other compounds which boil over a wide range. Those components boiling at the lower end of this range (between about 38° C. (100° F.) and 343° C. (650° F.)) are in many cases recovered from the crude oil by atmospheric distillation. For purposes of this patent specification and its various embodiments and claims, the term “hydrocarbon process fluid” refers either to crude oil or to any other hydrocarbon fluid that is suitable for refining by thermal, or thermo-chemical means such as thermal distillation, cracking, hydrogenation, steam cracking, fluid catalytic cracking, etc. The term “refined hydrocarbon product” refers to a hydrocarbon process fluid which has already been treated or refined.

In the molten metal reactors, one or more feed is directed into contact the each molten metal reactor to generate syngas. The syngas is combusted in either one or more syngas-fired burners, or a suitable combustor unit to generate heat to which a substantial quantity of radiant thermal energy is directed to heat exchangers which are provided at the process heaters 601, 602, 603, 604, 605 for heating of crude oil 1010, or also a general hydrocarbon process fluid 1010.

A fluid contact between the melt within the crucible 40 and the feed fuel material from an injector 511 causes partial conversion of the feed fuel material from the injector 511 into synthesis gas (syngas). The syngas is directed toward a heat exchanger device section 501, which is shown in the process diagram of FIG. 12. The heat exchanger section 501 causes cooling of the syngas to a pre-determined syngas temperature range. The conditioned syngas, which has a pre-determined temperature range, is passed and directed from a processed syngas outlet 530 to one or more heat producing burners placed within or in proximity to a process heater 601, 602, 603, 604, 605, which are shown in FIG. 8 and FIG. 9.

In the process heaters 601, 602, 603, 604, 605, the syngas which is taken off from the processed syngas outlet 530 shown in FIG. 12, is combusted with an oxidant gas such as air, oxygen, enriched oxygen, or mixtures thereof, to generate heat, which, by design of the process heater causes radiant or convective heat or a combination thereof. It is also possible to supply other fuels such as oils to the process heater or a multitude of process heaters. The heat from the combustion process is in turn used for heating a hydrocarbon process fluid 1010 to a pre-determined temperature range.

Generalized non-limiting examples of a heat exchanger devices 501 are provided by those manufactured by Tranter international AB, Oil & Gas Department, Stockholm, Sweden, or those described by another manufacturer Alstom (Power Energy Recovery) “Syngas Cooler Systems for Gasification Plants”, ALSTOM Power Energy Recovery GmbH.

In one embodiment, that is also indicated in FIG. 12, the syngas is conditioned or treated Why? prior to passing into fluid contact with the heat exchanger section 501 or after syngas cooling (after passing the heat exchanger section 501), to remove contaminants such as sulfur, tar, etc. This can be implemented using syngas cleaning equipment such as those manufactured by Dow (Gas Cleaning) and described in the publication “Biomass to Liquid”.

By way of example, the process heaters 601, 602, 603, 604, 605 shown in FIGS. 7 to 9 may be constructed according to examples such as those shown in the U.S. Pat. No. 4,658,762.

Additional references to process heaters include (but are not limited to) those designed and manufactured by Babcock & Wilcox, such as a Blast Furnace Gas-Fired Boiler for Eregli Iron & Steel Works (Erdemir), Turkey, the process heater/boiler having a total heat input of between 300,000,000 BTU/hr for natural gas fuel to 178,000,000 for a gas composition of up to 23% CO and 4% H2. Performance test operational data is also included within the mentioned publication.

FIG. 8 shows a crude oil refinery plant 1000′, which is similar to the one shown in FIG. 7. Different from the oil refinery plant 1000 of FIG. 7 and the combinations, alternatives and options described therewith, the oil refinery plant 1000′ of FIG. 8 comprises a parallel processing of a reduced crude feedstock 1011 Why?.

FIG. 9 shows a hydrocracking plant 1300. The hydrocracking plant 1300 comprises a primary hydrocracking reactor 1310, a first pass hydrocracking reactor 1320 and a second pass hydrocracking reactor 1330. The primary hydrocracking reactor 1310 is supplied with a feed stock from a feed conduit 1311. All three hydrocracking reactors 1310, 1320, 1330 are supplied with recycled feed from a recycling conduit 1312. The recycling conduit 1312 is connected to an input 1351 of make-up hydrogen via a make-up compressor 1350 and a recycle compressor 1360. An inlet 1361 of the recycle compressor 1360 is furthermore connected to effluent outlets 1321 and 1331 of the second and third pass hydrocracking reactors 1320, 1330 via a high pressure separator 1340 and a high pressure amine absorber 1341.

A bottom outlet of the high pressure separator 1340 is connected to a low pressure separator 1342. The low pressure separator 1342 comprises a bottom outlet for a product, which is connected to a fractionator that is not shown and a top outlet for a low pressure. An outlet of the recycle compressor 1360 is connected to the process heater 606 and to various inlets of the hydrocracking reactors 1310, 1320, 1330.

In a non-limiting example, and after the fractional distillation of naphtha in an oil refinery such as the one depicted in the preceding FIGS. 7 and 8, thermal cracking takes place in the hydrocracking section 1300 illustrated in FIG. 8, in order to break hydrocarbons into smaller molecules. The compression stage of the mixed cracked gases takes place in a multistage centrifugal compressor running at approximately 4,100 to 5,000 rpm Why?. Cooling of the cracked gases is achieved by using propylene at ≈40° C. and ethylene at ≈100° C. Why?. Evaporated propylene as well as ethylene is re-compressed using multistage centrifugal compressors running at between 3,800 and 10,000 rpm Why? respectively.

According to exemplary embodiments of the present specification, a refining of a hydrocarbon fluid is performed according to the following two methods A and B

Method A:

1. melting and heating electrically conductive material to form a melt, 2. contacting one or more carbon containing feed fuel, an oxygen-carrying gas, or a mixture, into melt to convert at least a portion of one or more carbon containing feed fuel into synthesis gas, 3. cooling synthesis gas to a pre-determined temperature range, 4. combustion of synthesis gas with an oxidant gas to generate heat, 5. passing a hydrocarbon fluid so as to receive radiant heating, convective heating or a combination thereof from the combustion of synthesis gas with oxidant gas.

Step (4) includes delivering cooled synthesis gas from the step of (3) at a pre-determined gas pressure range.

In another embodiment of Method A for refining a hydrocarbon fluid, the synthesis gas which is generated in one of the gasifiers of FIGS. 1 to 6 by providing a fluid contact between a feed fuel, oxidant gas into a melt, is treated and conditioned (such as cooling of the synthesis gas, premixing the synthesis gas with air or oxygen-carrying oxidant gas), and then piped for combustion in process heaters, boilers, combustion turbines, steam generators, heat producing burners, or a combination thereof.

In another embodiment of Method A for refining a hydrocarbon fluid, the generated synthesis gas generated is piped and directed into a process heater such as the process heater 606 shown in FIG. 9 to cause heating of a crude oil stream or hydrocarbon process stream to a pre-determined temperature range.

Method B:

1. maintaining a process of thermal distillation and or cracking of hydrocarbon fluid, 2. melting and heating electrically conductive material to form a melt, 3. contacting one or more carbon containing feed fuel, an oxygen-carrying gas, or a mixture, into melt to convert at least a portion of one or more carbon containing feed fuel into synthesis gas, 4. generating steam from a water flowstream by passing water flowstream to receive radiant, convective, or in combination, heating from synthesis gas, 5. supplying steam to the process of thermal distillation and or cracking of hydrocarbon fluid.

Method B comprises the use of a steam generator, which is not shown in FIG. 9. In the above method B, the steam generated from (4) is directed towards a steam cracking furnace for production, refining of a hydrocarbon process fluid into Ethylene, and depending on reaction and catalyst selection, various selective refining of propylene and other refined hydrocarbon products.

The steam quality required ranges between 750 to 850 degrees Celsius Why?, or 180 to 220 degrees Celsius (for Naphtha, ethane, propane Why?), at pressure drop of between 2 to 8 bar Why?.

According to an embodiment of the present specification, steam generated by step (4) of Method B for refining a hydrocarbon fluid is directed into the hydrocracking reactors 1310, 1320, 1330 for steam assisted cracking of an unrefined hydrocarbon process fluid.

In another embodiment of the abovementioned method B syngas generated from step (3) is passed into the steam generator at step (4) to reduce the temperature of the syngas to a pre-determined range, and the cooled syngas is piped via a delivery interface to one or more process heater comprising one or more heat producing burners to generate thermal heat for the performance of steps (4) and (5) of Method A so as to refine one or more hydrocarbon process fluid into one or more hydrocarbon refined products.

The steam generator of step (4) of Method B provides a diluting steam of a quality desired, to be directed towards a cracking furnace of the olefin producing section of the oil refinery (or hydrocarbon processing plant). The hydrocarbon process fluid is passed into the cracking furnace with the dilution steam of a specific quality, specification (such as steam temperature and pressure drop) to refine the process fluid into an Olefin product (or a “cracked” gas).

In yet another embodiment of the Method B, steam generated by step (4) is directed for use in a gas compressor drive that is operating in the Olefin section of the oil refinery 1000, 1000′. In one exemplary embodiment, cracked gas passing from the cracking furnace is compressed by an extraction-condensation steam turbine for purposes of compression drying the cracked gas, acid gas removal and preparation prior to passing the processed cracked gas into other sections of the oil refinery such as a C2 splitter unit or hydrogenation plant. An overview of steam cracking can be found in the publication “Selective Hydrogenation in Steam Cracking”.

In one non-limiting example of Method A and/or Method B, and with reference to step (4) and step (5) of Method A, the heat generated from combustion of synthesis gas generated from fluid contact of a feed fuel into the melt contained within a holder device in accordance to the embodiments of the present specification is transferred to cause thermal heating of the crude desalting and crude distillation section of a typical oil refinery.

Heating temperature ranges between 100 degrees Celsius to 175 degrees Celsius Why?, in other embodiments pre-heating temperature ranges between 210 degrees Celsius to 280 degrees Celsius Why?, in other embodiments the heating temperature ranges between 340 degrees Celsius to 410 degrees Celsius Why?.

The steps of heating or pre-heating means heating the crude oil stream input or hydrocarbon process fluid input flowing through the at least one process heater to a determined temperature range so as to cause refining and distillation or separation of one or more refined hydrocarbon product from the said crude oil stream input or hydrocarbon process fluid input.

In one embodiment the crude oil stream input or hydrocarbon process fluid is heated by heat generated from the steps described in Method A, Method B, and further directed into another process step (such as steam cracking unit, hydrocracking unit, distillation unit, etc), to yield the refined hydrocarbon product.

In another embodiment the refined hydrocarbon product is an intermediate material to be fed into another section of the oil refinery for further processing into its intended final refined product.

The other section of the oil refinery, or the other process step above may utilize a further process heater, or a heat exchanger unit.

This also means the steps described in Method A, Method B, and the various other examples in this specification relates to the extraction, or isolation of a determined range of hydrocarbons having selected boiling ranges, flash points, vapor pressures, and shall also mean extracting one or more product (sometimes referred to as product “cuts”) from a crude oil stream input or hydrocarbon process fluid input by use of a heat source, in particular heat source generated from the combustion of synthesis gas with an oxygen-carrying oxidant gas such as air, oxygen, or their derivatives, wherein the synthesis gas is generated by means of delivering one or more feed fuel into fluid contact with a molten metal, a melt, or their derivatives.

According to a further gasification method, which is referred to as “Method C”, a plurality of feed fuel materials is introduced into an oil refinery, such as the refineries 1000, 1000′ shown in FIGS. 7 and 8. The method comprises the steps of:

a) feeding a plurality of feed fuel materials, refinery flare gas exhaust and refinery residual material as a combined feedstock to a gasifier; b) gasifying the combined feedstock in the gasifier by fluid contact with a melt disposed within said gasifier to form syngas; and c) processing at least some of the syngas to form a syngas-derived product, wherein at least some of the syngas-derived product is utilized in the oil refinery.

Herein, a “refinery residual material” refers to carbonaceous by-products of an oil refining process such as asphaltenes, tars, and combinations thereof.

A gasifier can refer to a partial oxidation gasifier, a steam reformer, an autothermal reformer, and combinations thereof, and specifically includes gasifiers having a holder device for holding a molten metal, a molten melt material, molten metal alloys, derivatives and combinations thereof.

In one embodiment of Method C, the step of b) can also optionally include the provision of an oxidant gas such as air or oxygen, substantially pure oxygen, enriched oxygen air, or a mixture thereof, to cause partial oxidation within the melt of the gasifier of Method C.

In one embodiment of Method C, and of step c), syngas-derived product can mean hydrocarbons, H2, steam, electrical power, thermal heat from combustion of the syngas, mechanical shaft power, or derivatives and combinations thereof, to be used in the oil refinery.

An “oil refinery,” as defined herein, generally refers to an oil refinery, or aspects thereof, where crude oil (or other fossil fuels such as coal or natural gas) is processed. Processes carried out at such refineries include, but are not limited to, reforming, cracking, distilling, and the like.

“Refinery residual,” or “refinery resid,” as defined herein, generally refers to the heaviest by-product fractions produced at a refinery. Asphaltenes are a type of refinery resid, as is coker coke.

FIG. 10 shows a vacuum distillation plant 1201, which is also referred to as vacuum furnace 1210 or vacuum distillation section 1210.

The vacuum distillation plant 1201 comprises a vacuum distillation column 1200, which comprises an inlet for a reduced crude oil conduit. A process heater 605 is thermally in contact with the reduced crude oil conduit via a heat exchanger.

The vacuum distillation column 1200 comprises a first outlet for light vacuum gas oil (LVGO), a second outlet for heavy vacuum gas oil (HVGO), a bottom outlet for residue, also known as “resid”, and a gas outlet. The gas outlet is connected to a gas conduit which is in thermal contact with a heat exchanger. The gas conduit is connected to a gas reservoir, also known as a “receiver”. A top outlet of the gas reservoir and a bottom outlet of the gas reservoir are connected to vacuum jets. Different sections of the vacuum distillation column 1200 are connected via return loops, wherein the return loops are connected to heat exchangers. The return loops comprise pumps, which are not shown in FIG. 10.

In another embodiment, which is explained with reference to FIGS. 11 and 12, a syngas is produced in a gasifier which is remote from a hydrocarbon processing plant and the syngas is piped to the hydrocarbon processing plant for heating a process heater. Although the features of FIGS. 11 and 12 are explained with reference to a remote syngas production they are not limited to this case.

FIG. 11 shows a crucible 40, which is arranged within a gasifier 10′ and holds a melt such as the melt 90 of FIG. 1. The gasifier 10′ comprises one or more feed conduits, which are not shown in FIG. 11, for the supply of one or more feed fuel into fluid contact with the melt to cause generation of synthesis gas. A gas duct 141 is provided for capturing and directing the synthesis gas to a plant for cooling and gas conditioning of the synthesis gas to a pre-determined gas specification and temperature range. Such a plant may be provided by the syngas cooler 501, which is shown in FIG. 12.

According to the embodiment of FIG. 12, a crucible is arranged within gasifier 10′ to hold a melt 90 of FIG. 1, and one or more feed fuel is supplied into fluid contact with the melt 90 to cause generation of synthesis gas. The synthesis gas is captured and directed from duct 140 to the heat exchanger 501 of FIG. 12 and subsequently directed from the heat exchanger 501 of FIG. 12 to the process heater 601 of FIG. 8.

In the general sense, the heat exchanger 501 provides a plant for cooling and gas conditioning of the synthesis gas to a pre-determined gas specification and temperature range.

The process heater 601 is provided by a process heater-furnace designed to cause combustion of the synthesis gas provided from withdrawal-point 530 of FIG. 12, the process heater furnace 601 is further designed to pre-heat crude oil 1010.

In one embodiment, the synthesis gas from the withdrawal-point 530 of FIG. 12 is piped to process heater furnace 603 to cause heating of crude oil or hydrocarbon process fluid in a distillation column of an oil refinery to a desired temperature range to cause distillation into one or more refined products.

In one embodiment, at least one outlet conduit is provided in fluid communication with the metallic crucible and a first heat exchanger unit having a radiant heating coil, a convective heating coil, or a combination thereof, wherein first heat exchanger comprises at least one input passageway for the inflow of a first fluid and at least one output passageway for the outflow of a second fluid.

The first heat exchanger unit is adapted with a gas pipeline configured with one or more heat producing burner device arranged so as to cause combustion of synthesis gas with an oxygen-carrying oxidant gas. The second heat exchanger unit comprises a radiant heating coil, a convective heating coil, or a combination thereof, and is in fluid communication with a gas pipeline, one or more heat producing burner devices, or a combination thereof. The second heat exchanger comprises at least one input passageway for the inflow of a hydrocarbon process fluid and at least one output passageway for the outflow of a refined hydrocarbon product fluid.

The gas pipeline may be in fluid contact and or in fluid communication with the gas conduit 140 of FIG. 12, that is provided at the containment device 10′. An induction coil of the crucible, which is not shown in FIG. 12, is supplied with electrical power from power lines to cause melting and heating of a melt such as the melt 90 shown in FIG. 1.

FIG. 12 shows a gasifier 10′, wherein an approximate orientation of the crucible 40 is depicted that is formed similar to the crucible 40 of FIG. 2. The gasifier 10 comprises, among others, the metallic crucible 40, slag granulation units 101, 102, 103, and a gas input feed. More specifically, FIG. 12 shows a configuration of a STX Multifeed KF 280S plant, which is also known as “gasification island”, having a saturated/superheated steam block and having a 50 MW/30 MW capacity rating. FIG. 13 shows one or more gasifier trains 540 that are configured to receive one or more feed fuel to generate syngas 531.

In one embodiment, the syngas 531 is directed to one or more syngas burner (not shown) to generate heat to be supplied to determined sections of an oil refinery of FIG. 7, FIG. 8, FIG. 9, FIG. 10 or a combination thereof. Radiant heat and convective heat is deployed to pre-heat or heat crude oil or process hydrocarbon fluid into one or more refined hydrocarbon product.

In one embodiment the radiant heat and convective heat is deployed via one or more heat exchanger unit, one or more process heater, one or more furnace of the oil refinery of FIG. 7, FIG. 8, FIG. 9, FIG. 10, or a combination thereof, prior to or after crude oil passes the desalting step.

In one embodiment, the feed fuel comprises one or more feed material, and the syngas 531 is reacted with an oxidant for combustion and generation of heat, transferred via radiant and convective means to one or more heat exchanger unit for heating of hydrocarbon process fluid or crude oil in a hydrocarbon processing plant, such as the plants 1000, 1000′, 1300 shown in FIGS. 7, 8 and 9.

In one embodiment, the cooled syngas stream is directed from the syngas cooler 501 to a process heater, such as the process heater 601 of FIGS. 7 and 8, which is a process heater-furnace that is designed to cause combustion of the synthesis gas provided at the withdrawal-point 530 of FIG. 12 and that is further be designed to pre-heat crude oil 1010, as shown in FIGS. 7 and 8.

In one embodiment, the synthesis gas from the withdrawal-point 530 of FIG. 12 is piped to process heater furnace 603 shown in FIGS. 7 and 8 to cause heating of crude oil or a hydrocarbon process fluid in a distillation column of an oil refinery to a pre-determined temperature range to cause distillation into one or more refined products.

In another embodiment, the synthesis gas from the withdrawal-point 530 of FIG. 12 is piped to the process heater furnace section 606 shown in FIG. 9 to cause heating, hydrocracking, steam dilution, vacuum heating and refining into one or more refined products.

The gasifier 10 comprises the metallic crucible 40 and its associated components and sub-systems such as induction coil heater and power supply unit. The generated and conditioned syngas is piped from the remote site to a hydrocarbon processing plant, such as the plant of FIG. 7, which comprises the process heaters 601, 602, 603, 604, 605 for combustion in the various heat producing burners of the process heaters 601-605 in the hydrocarbon processing plant, in particular in an oil or hydrocarbon process fluid refinery plant.

The remote site 510 of FIG. 12 comprises the crucible 40 having a melt disposed therein. One or more feed fuel material is supplied into fluid contact with the melt from the injector 511. In addition, an oxidant gas such as air, oxygen, or a mixture, may be injected from the air compressor 512. The synthesis gas generated from the crucible 40 is then cooled to a pre-determined temperature range in cooler heat exchanger 521, and the syngas product 531 of the remote site 510 is piped via one or more gas flow pipes to a second site, such as the ones shown in the FIGS. 7-10, to be combusted with a oxidant such as air, oxygen, or a mixture, in one or more heat producing burners, such as the burners placed within process heaters 601, 602, 603, 604, 605 of FIG. 7.

At least one delivery interface in communication between the remote site and the hydrocarbon processing plant directs the synthesis gas to the process heaters 601, 602, 603, 604, 605 of FIG. 7.

The pressure and gas velocity, alongside gas temperature of the synthesis delivered via the delivery interface device between the first and second remote site is determined by one or more processor and in accordance to one or more control signal and control parameters.

In one embodiment, a delivery interface device comprises one or more gas flow pipelines made of a suitable material such as (in non-limiting example), steel alloys, Inconel alloys, titanium, stainless steels, tungsten and their various alloys, or gas flow pipelines made of a suitable material and then lined within their inner wall surface a refractory material or a pre-determined liner material that resists hydrogen corrosion (also called hydrogen-induced cracking (or corrosion) (HIC), hydrogen corrosion cracking (HCC), stress corrosion cracking (SCC), hydrogen embrittlement (HE), and delayed failure (Leighty, Hirara et al. 2003), of the pipeline material itself.

In another embodiment the delivery interface device or portions of the delivery interface device is above ground, while in other embodiments the delivery interface device or portions of the delivery interface device is located below ground.

According to the present specification, the different embodiments of crucibles disclosed in FIGS. 1-6 and 11, 13, 14 and in the corresponding descriptions which comprise, among others, different realizations of metallic or non-metallic crucibles cooling means, inductive or electric heaters and production methods for crucibles can be combined with each other. Furthermore, the crucibles according to the present specification can be combined with a hydrocarbon processing plant according to FIGS. 5 to 8 and with a flue gas supply according to FIG. 13.

The present specification discloses, among others, various embodiments of methods and means of communication between a gasifier according to the present specification and a plant for processing a process fluid, such as a hydrocarbon containing process fluid and in particular for processing a hydrocarbon containing process fluid which is derived from crude oil via distillation, cracking, hydrocracking, hydroprocessing, hydrotreating, reforming, alkylation, polymerization, product blending or other processes.

These various methods and means are illustrated by FIGS. 7 to 10 and the corresponding figure descriptions and by FIGS. 15 to 17 and the corresponding figure descriptions. Furthermore, they are illustrated by the following descriptions of embodiments which are grouped according to eight different aspects of communication.

According to the several aspects of communication, a processing plant with a gasifier device is provided for converting one or more feed fuel to syngas, such as for example the gasifier devices in FIG. 1, 5, 11, wherein the gasifier device comprises a crucible for holding a metallic material and an electric induction heater in the vicinity of the crucible. The electric induction heater is provided for melting and inductive heating of the metallic material to form a molten material disposed within the crucible, such as for example the layer of molten metal and the slag layer shown in FIG. 1. In particular, the electric induction heater may be provided by an induction coil which surrounds the crucible, such as shown in FIG. 1 or FIGS. 3, 4 and 5.

The gasifier device comprises at least one feeding conduit, such as for example the overhead lance 52 of FIG. 1 or the feeding conduits 50, 51 in the bottom of the crucible of FIG. 1 for providing a flow stream of one or more feed fuel to be delivered into contact with the molten material to convert at least a portion of the feed fuel to syngas. In general, the feeding conduit may extend through a side wall of the crucible, through a bottom surface of the crucible, or from above into an interior region of the crucible. In the latter case it may comprise or be connected to an overhead lance.

Furthermore, a liquid cooling arrangement is provided for cooling at least a portion of the crucible. A supply conduit, such as the downstream application conduit of FIG. 1, is provided for delivering the syngas to the exterior of the crucible. Furthermore, the processing plant according to the abovementioned aspects of communication comprises a hydrocarbon processing plant for processing a hydrocarbon based process fluid. The present specification provides various examples of hydrocarbon processing plants, in particular of hydrocarbon processing plants for use in a crude oil refinery, such as those shown in FIGS. 7 to 10 and FIG. 17. However, the embodiment is not limited to those examples.

In a first aspect, the present application discloses a means for supplying heat from a crucible to a hydrocarbon processing plant. According to the first aspect, the processing plant further comprises a hydrocarbon processing plant for processing a hydrocarbon based process fluid, such as the processing plants shown in FIGS. 7, 8, 9, 10 and 17 and a heat extraction unit for providing heat energy from the gasifier device to the hydrocarbon processing plant, such as the heat extraction units shown in FIGS. 7, 8, 9, 10 and 15.

Furthermore, the heat energy from the gasifier device may also be used to provide heat to auxiliary or supporting processes in a hydrocarbon processing plant, for example to a desulfurization process such as the Claus process, the SCOT (Shell Claus Off-gas Treating) process, the Beavon process or the like, to flue gas purification methods, such as the Wellman-Lord process or others, to a steam reforming process, or to a wastewater treatment. For example, the heat may be used in a reheater of the Claus process.

The heat extraction unit is in fluid communication with at least one supply conduit of the gasifier device, such as the downstream application conduit 140 of FIG. 15. The heat extraction unit comprises a heat exchanger that is in thermal contact with at least one section of the hydrocarbon processing plant. This is illustrated by way of example in FIG. 15.

According to further embodiments of the first aspect, the heat extraction unit comprises a burner, wherein an inlet section of the burner is operationally connected to the supply conduit, such as the burner 608 of FIG. 15.

According to a second aspect of communication, a discharge material conduit extends between a discharge section of the hydrocarbon processing plant and a feeding conduit of the crucible. An example of a discharge material conduit is given by the conduit 1207 of FIG. 16. According to the present specification, the discharge material conduit does not need to be connected to a top section of a distillation tower, as shown in FIG. 16, but it may also be connected to a middle or to a bottom section of a distillation tower or to a section of a reactor for converting hydrocarbons into a refined product.

In one embodiment according to the second aspect, the discharge material conduit comprises a unidirectional feed element providing essentially a one-way flow of discharge material from the hydrocarbon processing plant to the feeding conduit of the crucible. The unidirectional feed element may be provided, for example, by a one-way valve, a pump, a check valve, a non-return flap or further directing means.

According to a third aspect of communication, which is shown in particular in FIG. 15, the processing plant comprises a heat extraction unit for providing heat energy from the hydrocarbon processing plant to the gasifier device. The heat extraction is in fluid communication with at least one section of the hydrocarbon processing plant. Furthermore, the heat extraction unit comprises a heat exchanger which is in thermal contact with at least one section of the gasifier device.

According to a fourth aspect, which is depicted in FIG. 16, a sensor is provided, which is in contact with an area of the hydrocarbon processing plant and which provides a sensor signal that is derived from a measured process parameter of the hydrocarbon processing plant such as pressure, temperature, inflow of process fluid, outflow of refined process fluid or supply of additives and other reactants.

A process control means is provided for controlling the gasifier device in response to the sensor signal, for example for adapting process parameters, such as adapting a supply of feed fuel or oxygen, which in turn cause a decrease or an increase in an output rate of syngas.

According to a fifth aspect of communication, which is depicted in FIG. 16, a sensor is provided which is in contact with an area or a portion of the gasifier device and which provides a sensor signal. Furthermore, a process control means is provided for controlling the hydrocarbon processing plant in response to the sensor signal.

According to a sixth aspect of communication, the gasification device for converting the one or more feed fuel to syngas comprises a generator unit for providing electric energy to the hydrocarbon processing plant. Herein, “comprising” also refers to an arrangement in which the generator is connected to the gasification device or to a supply conduit such as a downstream application conduit of the gasification device.

In one embodiment of the sixth aspect the generator unit uses heat energy from the device for converting the one or more feed fuel to syngas for providing electric energy, for example by employing a heat pump, or a Stirling engine. The heat energy and/or the syngas may be used to power a steam turbine or gas turbine to generate electric energy or to power the various pumps, actuators etc. of the hydrocarbon processing plant, or to power an electric furnace to generate heat to refine crude oil or process fluid into refined products. Some of these appliances are shown in FIG. 17.

In another embodiment according to the sixth aspect, the generator unit uses syngas from the device for converting the one or more feed fuel to syngas for providing electric energy, for example by burning the syngas in a combustion motor, or in a gas turbine, such as the gas turbine of FIG. 17.

According to a seventh aspect of communication, the processing plant comprises a generator unit for providing electric energy to the device for converting the one or more feed fuel to syngas. According to an embodiment of the seventh aspect, the generator unit uses heat energy from the hydrocarbon processing plant for providing electric energy for example by employing a heat pump or a Stirling engine.

According to another embodiment of the seventh aspect, the generator unit uses fuel material stream from the hydrocarbon processing plant for providing electric energy, for example by employing a combustion engine or a gas turbine, as shown in FIG. 17.

According to an eighth aspect of communication, a syngas conduit extends between the supply conduit and a receiving section of the hydrocarbon processing plant. This applies in particular to the hydrocarbon processing plants of FIGS. 7 to 10 and 17. The connection between the gasifier and the hydrocarbon processing plant according to the eighth aspect can be best seen in FIG. 15. In one embodiment, the supply conduit is connected to a bottom part of a distillation tower. If there is an excess of residue which is not economical to sell as asphalt or as fuel, the supply conduit can be used to process the excessive residue in the gasifier.

According to another embodiment, the hydrocarbon processing plant is in communication with the device for converting the one or more feed fuel to syngas, wherein communication may in particular refer to the unidirectional or the bidirectional transfer of material, heat energy, electric energy or information or to a combination thereof, such as depicted in the FIGS. 15 and 16.

According yet another embodiment, the present application discloses a processing plant comprising a holder unit, such as a crucible or a reactor vessel, that defines a hollow for holding a molten metallic material. At least one heater unit is disposed in proximity to the holder for heating the hollow. The heater unit may in particular comprise an induction coil, such as depicted in FIGS. 1, 3, 4, 5, 6, or it may comprise a heating resistance, a combustion heating, an electric arc or other heating means, such as a plasma driven heater.

At least one feeder unit for providing a flow stream of one or more combustible material to be delivered into the hollow. A cooler unit is provided for cooling the holder, the cooler unit being disposed in proximity to the holder unit, wherein “in proximity” also comprises the case in which the cooler unit is partially or completely integrated into a body of the cooler unit.

At least one supply conduit, such as the downstream application conduit of FIG. 1, is provided for supplying an output gas stream from the hollow to the exterior of the holder unit. In particular, the supply conduit may be part of a communication means.

The processing plant comprises a hydrocarbon processing plant for processing hydrocarbon based polymers. A communication means provides communication between a holder interface of the holder unit and a plant interface of the hydrocarbon processing plant, in particular for the unidirectional or bidirectional transfer of material, heat energy, electric energy or information. In the latter case, the communication means may also comprises a wireless transmission path.

According to the first to eighth aspect of communication between a gasifier and a hydrocarbon processing plant according to the current specification, which are shown in the FIGS. 15 and 16, a method of processing a hydrocarbon based process fluid is disclosed.

An electrically conductive material is placed within a metallic crucible and the electrically conductive material is heated to form a molten material disposed within the metallic crucible. The molten material is maintained in a molten state, for example by continuing to provide inductive heating or any other kind of heating.

At least a portion of the crucible, such as a metallic inner surface of the crucible, is cooled with a cooling liquid. A flow stream of one or more feed fuel is delivered into contact with the molten material and thereby at least a portion of the feed fuel to is converted to syngas which is extracted from the crucible.

According to a first aspect of communication, which is shown in 15 or also in FIGS. 7 to 10, the method furthermore comprises transferring heat energy from the extracted syngas to the hydrocarbon based process fluid. As explained above, the heat energy may be employed in various ways such as for preheating of crude oil, or for supplying reheaters, superheaters or other heaters of the hydrocarbon processing plant with heat energy.

According to an embodiment of the first aspect, the extracted syngas is combusted and the combustion heat is transferred to the hydrocarbon based process fluid. According to another embodiment, the heat energy is extracted from the syngas by a non-chemical process such as heat conduction.

According to another aspect of communication, which is shown in FIG. 16, the gasification method further comprises transferring a portion of the hydrocarbon based process fluid to the molten material. One possible use is the utilization of hydrocarbon products, such as resid, which cannot be economically sold. The cost effectiveness depends on the current market conditions, among others and may vary over time. Likewise, the amount of transferred material may be controlled according to economic constraints. According to one embodiment of the second aspect, the flow stream of one or more fraction of a hydrocarbon based process fluid is essentially a one-way flow stream.

According to a another aspect of communication, which is shown in FIG. 15, the method comprises transferring heat energy from the hydrocarbon based process fluid to the flow stream of the one or more feed fuel. In this method, “feed fuel” can in addition comprise additional gases such as oxidizing gases.

According to a another aspect of communication, which is shown in FIG. 16, a process value of the hydrocarbon based process fluid is measured and the conversion of the one or more feed fuel to syngas is controlled in response to the sensor signal. Process values, which are also referred to as process parameters, may comprise, but are not limited to, temperature, vapor pressure, concentration of reactants, an intensity of mixing such as a stirring speed, or an inflow and outflow of material.

According to a another aspect of communication, which is shown in FIG. 16, the gasification method comprises measuring a process value of the conversion of at least a portion of the one or more feed fuel to syngas and controlling the processing of the hydrocarbon based process fluid in response to the sensor signal.

According to the another aspect, electric energy is generated from the syngas by using the heat content and/or the chemical energy of the syngas and the generated electric energy is used for the processing of the hydrocarbon based process fluid, for example by pumping, heating, stirring, shaking, mixing, electrolysis, switching valves, lighting and thereby influencing one or more steps of processing the hydrocarbon process fluid.

According to one embodiment of the above another aspect, heat energy is extracted from the syngas for the generation of the electric energy, for example by using a heat pump or a Stirling engine. According to another embodiment of the above another aspect, the syngas is combusted and electric energy is generated from the combustion of the syngas, such as in the gas turbine of FIG. 17.

According to another aspect, the method comprises generating electric energy from the hydrocarbon based process fluid and using the generated electric energy for the conversion of the one or more feed fuel to syngas. In particular, the electricity can be used to provide electric power to appliances and thereby causing reactant supply, product extraction, pumping, heating, stirring, shaking, mixing, electrolysis, switching valves, lighting, etc.

In one embodiment of the above another aspect, the method comprises extracting heat energy from the hydrocarbon based process fluid for the generation of the electric energy, for example by using a heat pump or a Stirling engine.

According to another method of the above another aspect, the method comprises combusting a portion or a residue of the hydrocarbon based process fluid and generating the electric energy from the combustion of the hydrocarbon based process fluid. By way of example, the burners of FIGS. 7 to 10 or the gas turbine 1221 of FIG. 17 may be fired by syngas

According to another aspect at least a portion of the syngas, which is generated in the gasification process, is transferred to the hydrocarbon based process fluid in the hydrocarbon processing plant.

According to a further embodiment, a method of processing a hydrocarbon based process fluid is disclosed which comprises placing a metallic material within a hollow, as for example the interior of a metallic crucible, such that it is in contact with a metallic surface of the hollow, as for example an interior surface of a metallic crucible. The metallic material is melted to form a molten metallic material and maintaining the molten metallic material in a molten state.

The metallic surface of the hollow is cooled with a fluid, which may be a liquid or also a gas-liquid mixture. The cooling is provided either from inside the crucible by a cooling means such as conducts, which is provided in the body of the crucible, or from outside the crucible by a cooling means which is provided close to or on the outer walls of the crucible.

One or more flow stream of one or more hydrocarbon-containing material is brought into contact with the molten metallic material. The reaction gas is extracted from the hollow. Furthermore, a communication is established between the hollow and the hydrocarbon based process fluid. This may be a one-way or a two way communication and it may in particular be provided according to one of the abovementioned aspects 1 to 8. By way of example, the communication may comprise transfer of material, transfer of heat, transfer of measurement values and transfer of electricity in both directions.

FIG. 13 shows a further embodiment in which flue gas or exhaust gas containing carbon dioxide is collected from one or more remote sites such as a fossil-fired power plant, the exhaust outlet of a combustion engine system or the exhaust of a fuel-fired boiler-furnace unit. The flue gas is compressed and delivered into fluid contact with the electrically conductive melt disposed within metallic crucible in accordance to the previous embodiments of the present specification. The flue gas is compressed to a desired absolute gas pressure that exceeds at least the hydrostatic pressure of the electrically conductive melt disposed within metallic crucible.

With reference to FIG. 13, a remote site 2110 provides a supply of flue gas exhaust containing carbon dioxide, nitrogen and other trace gas elements 2111, to a gas storage plant 2070. The gas storage plant 2070 is configured to receive the flue gas exhaust 2111 from a remote site 2110 at a pre-determined pressure absolute range, depending on the remote site 2110, which may be a fossil fueled powerplant such as a coal-fired powerplant, a gas-fired, or oil fired powerplant. The remote site 2110 may further be provided by an incineration plant having a stack that emits flue gas exhaust 2111, or by an internal combustion engine set such as a gas turbine set or reciprocating engine set. In another embodiment, the remote site 2110 may be also be provided by a boiler or a furnace plant that combusts a fuel thereby generating the flue gas exhaust stream 2111.

The gas accumulator plant 2070 is arranged to receive from remote site 2110 the flue gas exhaust 2111 via one or more flow pipes, gas flow valves and pumps, pressurizers (to regulate the pressure absolute) of the flow gas pressure within either selected sections of such flow pipes or other associated parts (not shown).

In one embodiment, the remote site 2110 provides the flue gas exhaust 2111 at a first pressure absolute to the gas accumulation plant 2070, and the gas accumulation plant 2070 is configured with one or more flow pipes, gas flow valve, gas pressure pumps, gas pressure regulation devices, or a combination, to provide a pressurized flow stream 2060, 2061 to be delivered into contact with a melt 90 within the gasifier 10.

A gas compressor 2020 is arranged to be in fluid communication with the gas accumulation plant 2070 to receive the stored flue gas exhaust 2111 that is stored within the gas accumulation plant 2070, and compressor 2020 compresses a portion of the flue gas exhaust 2111 into a pressurized flow stream 2060, 2061. In one embodiment, the pressurized flow stream 2060, 2061 is prepared to a pre-determined gas flow pressure that is greater or equal to the hydrostatic head pressure of the melt 90 disposed within the molten metal gasifier 10.

The gas accumulation and/or storage unit 2070 is adapted to receive one or more flow stream of flue gas 2111 from one or more flue gas exhaust site 2110 such as oil, gas or coal fired powerplant, a boiler-combustion unit, a steam generator, a heat recovery steam generator unit, an incineration plant, or a combination thereof.

In some instances, the pressure of the flue gas exhaust 2111 and the resultant backpressure within the flue gas exhaust site 2110 cannot be varied beyond a determined operational range, such as flue gas exhaust from a gas turbine or reciprocating cycle engine set. The flue gas exhaust 2111 is captured and directed into storage in the gas accumulator plant 2070, which in turn supplies a predetermined flow stream of captured flue gas to one or more gas compressor 2020 to generate a pressurized flow stream of flue gas 2060, 2061. The pressurized flue gas is then delivered through conduits such as 50, 51, 2050 of FIG. 13 or a combination thereof, and/or through an overhead lance conduit, as shown in FIG. 13.

In one mode, the pressurized flue gas stream is at least pressurized greater than the hydrostatic pressure of the molten metal disposed within each molten metal reactor, and in some instances considerably more so as to control the introduction of the pressurized flue gas at a desired flow rate.

Especially for cases in which the flue gas exhaust is generated from an internal combustion engine system, a gas turbine, or a boiler-furnace set, the back pressure of the flue gas may be limited to within an acceptable performance range. The accumulator plant mitigates such a limitation by allowing captured flue gas to be stored prior to withdrawal for gas compression to produce a pressurized flue gas stream within a predetermined pressure range.

An estimate of the required pressure for an injection via an opening can be made by computing the hydrostatic pressure of the molten metal. The hydrostatic pressure refers to the weight pressure of the material above the flue gas injection opening. The weight pressure depends on the material density and the distance of the injection opening below the surface. The material density in turn depends on the material composition and temperature. Other relevant parameters comprise the material viscosity and the partial pressure of dissolved gaseous materials.

An impeller or compressor can then be adjusted to generate a pressure which is at least equal to the estimated molten metal hydrostatic pressure. In another embodiment, a flow rate of flue gas is measured and a power supply to the compressor is increased until the flow rate is equal to or greater than a predetermined target flow rate of flue gas. In one embodiment, a flue gas pressure may is adjusted by adjusting an opening position of a throttle which is in fluid communication with the compressor.

In one embodiment the accumulator plant comprises at least one flue gas storage tank, and in another embodiment of the present specification, the accumulator plant comprises a multiplicity of gas storage tanks. In another mode the accumulator plant has one or more single directional valve to control the flow of flue gas exhaust into the accumulator, and one or more isolation valve to control the withdrawal flow of flue gas from the accumulator to the gas compressor unit.

Furthermore, flue gas treatment units may be provided between a flue gas exhaust pipe of the powerplant and the accumulator gas tank or system. For example, the flue gas treatment units may comprise an amine absorption unit, a membrane unit, a zeolite pressure swing absorption unit, a selective catalytic reactor, an electrostatic precipitator or a flue gas desulfurization unit.

By way of example, the gas compressor 2020 may be provided by an electric drive system, a hydraulic-driven system, a pneumatic-driven system, or it may be mechanically coupled with a gas exhaust turbine, a steam turbine, or a gearbox drive that is powered by a primer mover unit such as an electric motor. The electric motors or the electric drive system may comprise an AC (alternating current) or a DC (direct current) electric motor device. The gas compressor 2020 may also be driven by an internal combustion reciprocating engine set, or derivatives thereof.

The gas accumulation plant 2070 may further comprise pumps, valve pressure regulators and other associated pressure monitoring and control devices to regulate the flow of flue gas exhaust 2111 to be flowing at first pressure absolute that does not interfere with the operational efficiency or operational mass flow of the remote site 2110.

According to the present specification a “Flue gas exhaust” refers, among others, to a gas containing CO, CO.sub.2 (carbon dioxide), nitrogen, nitrogen oxides and other particulates, sulphur compounds, soot, tar, or combustion exhaust gases generated from fossil-fuel power plants such as oil, coal, gas-fired powerplants, boilers, steam generators, combustion burners, gas turbine exhausts or reciprocating engine exhaust gases. The combustion engine may be provided by an internal combustion engine or an external combustion engine.

According to one embodiment, a pressurized flow stream 2060 of flue gas exhaust 2111 is delivered from above at a pre-determined gas flow pressure absolute and gas velocity through a conduit 2050 and an overhead lance 2051 and into fluid contact with the melt 90. In another embodiment, which is not shown in FIG. 13, the flue gas exhaust 2111 is delivered from above into fluid contact with a layer of molten slag 100 and from there into the melt 90. This may be achieved by extending the overhead lance 2051 into the layer of molten slag 100.

In another embodiment of the present specification a pressurized flow stream 2061 of flue gas exhaust 2111 is delivered from below at a desired gas flow pressure absolute and gas velocity through a conduit 50, 51 or a combination thereof, and into fluid contact with the melt 90. In another embodiment, which is not shown in FIG. 13, the pressurized stream 2060 of flue gas exhaust 2111 is delivered through the crucible bottom or through a crucible side wall into fluid contact with a layer of molten slag 100 and into the melt 90. In one exemplary embodiment, this is achieved by extending the conduits 50 or 51 to above the surface of the melt 90 into the layer of molten slag or by providing a conduit through one of the side walls of the crucible which contacts the layer of molten slag 100.

The conduit 2050 is connected to an overhead type lance device 2051, or similar arrangements where a conduit device is partially immersed into fluid contact with the melt 90, while the conduits 2050, 2051 are fully immersed conduits below the surface of the melt 90. In another embodiment, which is not shown in FIG. 13, conduits such as 2050, 2051 are arranged to be into fluid contact with the melt 90 from a side wall surface region of gasifier 10.

In another embodiment within this said mode of the present specification, the flue gas is delivered together with another flow stream of a second feed fuel. In yet another embodiment, the flue gas is delivered via a first conduit and second feed fuel delivered via a second conduit both of which are to be introduced and placed into contact with electrically conductive melt disposed within the metallic crucible.

In one exemplary embodiment, the pressurized flue gas is delivered via conduit 2051, and a second feed fuel such as coal, biomass, tar sands, shale, crude oil, raw sewage, or a determined carbon-containing feed material is delivered into fluid contact with melt 90 via conduits 2050, 2051, or vice versa (second feed fuel delivered via conduit 2051, pressurized flue gas 2111 delivered via conduits 2050, 2051, or combinations thereof.

In other combinations the pressurized flue gas 2060, 2061 is piped through the conduit into fluid contact with melt 90 with entrained particles of the second feed fuel such as coal, biomass, etc.

According to an embodiment of the present specification, a processing plant is disclosed, among others, which comprises a device for converting one or more feed fuel to syngas, such as for example the gasifier device 10 of FIG. 13. The device for converting the one or more feed fuel to syngas comprises a crucible for holding a metallic material and an electric induction heater that is placed in the vicinity of the crucible, such as the induction coil 120 shown in FIG. 13.

The electric induction heater is provided for melting and inductive heating of the metallic material to form a molten material disposed within the crucible, such as the molten metal layer 90 and the slag layer 100 of FIG. 13. The device comprises a feeding conduit for providing a flow stream of the one or more feed fuel to be delivered into contact with the molten material to convert at least a portion of the one or more feed fuel to syngas.

A liquid cooling arrangement for the crucible is arranged in proximity and/or within the crucible, such as the cooling arrangements of FIGS. 2 and 5, for example. For simplicity, this cooling arrangement is not shown in FIG. 13.

At least one supply conduit, such as the downstream application conduit 140 of FIG. 13, is provided for delivering the syngas to the exterior of the crucible. The processing plant further comprises a flue gas accumulator plant for processing a flue gas, such as the flue gas accumulator plant 2070 of FIG. 13. A flue gas discharge conduit extends between a discharge section of the flue gas accumulator plant and a feeding conduit of the crucible, such as for example the 2060 and 2061 of FIG. 13.

The exhaust conduit may extend through a side wall of the crucible, through a bottom surface of the crucible, or from above into an interior region of the crucible. In the latter case, the exhaust conduit may comprise or it may be connected to an overhead lance, such as the overhead lance 2051 of FIG. 13. Herein, the feed fuel may be provided by the flue gas only or it may comprise other compounds such as carbonaceous compounds, for example.

According to one embodiment, the flue gas discharge conduit comprises a unidirectional feed element which provides essentially a one-way flow of discharge material from the flue gas accumulator plant to the feeding conduit of the crucible. The directional feed element may be provided by a one-way compressor, a one-way valve, arrow shaped guide plates etc.

One function of the flue gas could be a slowing down of the reaction, similar to the injection of N2. As a further function, a flue gas which contains hydrocarbons can serve as a feed material to generate syngas. Apart from hydrocarbons, a typical flue gas will also contain compounds with oxygen, such as CHxOy and NOx. When they are broken up, the oxygen can be used in the reaction process.

According to another embodiment, a processing plant is disclosed, such as the processing plant in FIG. 13, that comprises a device for converting one or more feed fuel to syngas, such as the gasifier device 10 of FIG. 13. The device comprises a substantially metallic crucible which encloses a hollow with a metallic surface for holding a metallic material in the hollow. In particular, the hollow may be provided by a crucible or a reactor vessel and the metallic surface may be provided by an inner surface of the crucible or reactor vessel.

A heater is disposed in proximity to the metallic crucible, such as the induction coils shown in FIG. 13, wherein the heater is adapted to provide inductive heating of the crucible. However, other types of heaters may also be used in this embodiment such as for example furnace heaters and electric resistance heaters. A fluid cooling arrangement, such as the cooling arrangements of FIGS. 2 and 5, which may be used in combination with the device of this embodiment, is disposed in proximity to the metallic crucible.

A feeding conduit, such as the overhead lances 2050 and 2051 of FIG. 13 or the feeding conduits 50, 51 of FIG. 13, extends between the outside of the crucible and the inside of the crucible. Furthermore, a supply conduit extends between the inside of the crucible and the outside of the crucible. The processing plant further comprises a flue gas accumulator unit, such as the flue gas accumulator plant of FIG. 13, and a flue gas discharge conduit, such as the conduits 2050 and 2051, which extends between a discharge section of the flue gas accumulator unit and a feeding conduit of the crucible.

According to a further embodiment, the processing plant comprises a holder unit that defines a hollow for holding a molten metallic material, wherein a heater unit is disposed in proximity to the holder for heating the hollow.

The processing plant further comprises a feeder unit for providing a flow stream of one or more combustible material to be delivered into the hollow, which may be provided by a conduit or also by a conveyor belt or a similar conveying means.

A cooler unit for cooling the holder is disposed in proximity to the holder unit, which may comprise conduits and passageways, as in FIG. 2 or also an outer container, as in FIG. 5.

A supply conduit, such as the downstream application conduit of FIG. 13, is provided for supplying an output gas stream from the hollow to the exterior of the holder unit. A flue gas accumulator unit is provided for processing flue gas from a combustion process, for example flue gas stemming from a combustion process of a coal fired powerplant.

Furthermore, a communication means provides communication between a holder interface of the holder unit and a flue gas accumulator interface of the flue gas accumulator unit.

Furthermore, the current application provides a further gasification method for converting one or more feed fuel to syngas, wherein the feed fuel may be partially or essentially exclusively comprised of fuel gas.

An electrically conductive material is placed within a metallic crucible. The electrically conductive material is inductively heated to form a molten material disposed within the metallic crucible, such as the molten metal layer 90 and the slag layer of FIG. 13. The molten material is maintained in a molten state.

At least a portion, for example a metallic inner surface, of the crucible is cooled with a cooling liquid. Flue gas from a combustion process is stored in a flue gas storage plant. The stored flue gas is withdrawn from the flue gas storage plant in a controlled way and the flue gas is delivered into contact with the molten material. Thereby, at least a portion of the flue gas is converted into syngas. The syngas is extracted from the crucible.

According to a further embodiment, the method further comprises delivering a further feed fuel into contact with the molten material, thereby converting at least a portion of the one or more additional feed fuel to syngas. In particular if the first feed fuel comprises flue gas with a low combustion value, the syngas yield may be enhanced by providing a further feed fuel.

According another embodiment, which, by way of example, is depicted, in FIG. 13, the current specification discloses a method, that comprises placing a metallic material within a hollow such that it is in contact with a metallic surface of the hollow, wherein the hollow may be provided, by way of example, by an interior region of a crucible or a reactor vessel.

The metallic material is melted, for example by inductive heating, to form a molten metallic material and the molten metallic material is maintained in a molten state.

The metallic surface of the hollow is cooled with a cooling fluid, for example by conduits or passageways which are provided in or close to the hollow or by an outer container comprising the cooling fluid. In one embodiment, the cooling is provided such that the molten material forms a protective layer at the metallic surface of the hollow. Flue gas from a combustion process is delivered into contact with the molten material and a reaction gas is extracted from the hollow.

In an embodiment not shown here, an electrical resistance heating coil replaces the induction coil 120 of the embodiment of FIG. 13 to form additional embodiments. All variations described above can be applied, and the electrical resistance heating coil is brought into close thermal contact with the crucible 40. Thermally conductive material can be provided in the vicinity of the electrical resistance heating coil in order to improve heat transfer to the crucible 40.

In another embodiment not shown here, one or more electrical resistance coils are provided inside the hollow which is defined by the crucible 40, in order to bring the electrical resistance heating coil in close contact with the melt 90 and molten slag 100. Such electrical resistance coils can be provided together with one or more inductive coils 120 and—in a further embodiment—also together with both an electrical resistance heating coil and with one or more inductive coils 120. Cooling as described above with reference to FIG. 13 enhances the durability of the crucible 40.

FIG. 14 shows an induction heated metal refining reactor 10″ having a fluid cooled crucible which is similar to the gasification reactors 10 and 10′. Parts which are similar to parts in preceding embodiments have the same reference number and are not explained again. The metal refining reactor 10″ or a similar reactor is suitable for carrying out the metal refining methods mentioned below. In one embodiment, the overhead lance 52 is used to provide gaseous components or carbon containing feed fuel, similar to the gasification reactor of FIG. 1, or also further additives to the melt. In a further embodiment, the overhead lance 52 is adapted to deliver a metal containing material. In one embodiment in which a carbon hydroxide containing feed fuel is supplied, a reaction gas, such as syngas, is withdrawn from the exhaust conduit 140, as shown in FIG. 14.

The metal refining reactor 10″ comprises a feed conduit 53 with a cover flap 54. During or before a metal refining process, the cover flap 54 is opened and the metal refining reactor 10″ is loaded with a metal-containing material 91, such as iron ore, manganese ore, stibnite, other metal ores, other metal-containing rocks or metal-containing waste.

The crucible 40 of the metal refining reactor 10″ is provided with a cooling arrangement that is not shown in FIG. 12. Exemplary embodiments for cooling arrangements of the metal refining reactor 10″ are shown in FIG. 2 and FIG. 5. Further cooling arrangements which are suitable for use in the gasifier 10 of FIG. 1 may also be used for the metal refining reactor 10″ of FIG. 14.

During or after the metal refining process, a refined metal containing material is extracted from the crucible 40 through a discharge channel 110′ or through the central opening at the top of the crucible 40. In a particular embodiment, a tilting mechanism is provided for tilting the crucible 40 and discharging the refined metal containing material through the discharge channel 110′ or through the central opening.

In one embodiment, which is used for refining stibnite, the feeding conduits of the metal refining reactor 10″ are adapted for delivering a milled stibnite powder into contact with the melt 90 and for injection a carbonaceous additive according to the method steps (b) and (c) of the stibnite refining process mentioned below.

In a metal refining method according to the application, metal ore or ores containing metals are first milled to a desired sieve size and pre-heated to a desired pre-processing temperature, and introduced into contact with electrically conductive melt disposed within metallic crucible.

Non-limiting embodiment to refine antimony from stibnite (ore):

BACKGROUND

Stibnite was named in 1832 from the Latin “stibium”. It is a sulfide of antimony, Sb2S3. Its common color for stibnite is lead-gray with metallic luster. It forms long-columnar crystals sometimes in bunches, and is found in a number of ores. Antimony is used as a hardening alloy for lead, especially storage batteries and cable sheaths, also used in bearing metal, type metal, solder, collapsible tubes and foil, sheet and pipes, and semiconductor technology. A variety of compounds containing antimony as the major constituents were also used for various ammunition types such as detonators, tracer bullets and armory. The start of mass production of automobiles gave a further boost to antimony, as it is a major constituent of lead-acid batteries. The major use for antimony is now as a trioxide for flame-retardants (see for example the USGS commodity profile on antimony of 2004).

Overall, it is estimated that the distribution of antimony uses and consumption worldwide is flame retardants 72%, transportation including batteries 10%, chemicals 10%, ceramics and glass 4%, and other 4%. The USA, Japan and Western Europe which together account for around 70% of world demand dominate world consumption of antimony.

Antimony is one of very few substances (bismuth and water are two others) which expands when it cools and freezes. Industrially, stibnite (Sb2S3) is the predominant ore of interest and importance. Stibnite deposits are usually found in quartz veins. The deposits frequently contain minor amounts of gold, silver and mercury sulfides.

A list of known antimony minerals is provided below:

Horsfordite Cu6Sb Meneghinite Pb4 Sb2 S7 Aurostibite AuSb2 Livingstonite HgSb4 S7 Ullmannite NiSbS Stibioluzonite Cu3 (Sb,As)S4 Stibiobismuthine (Bi,Sb)4S7 Gerstleyite Na2 (Sb,As)8 S13•2H2O Freibergite (Cu,Ag)12Sb4S13 Stibiocolumbite Sb(Nb,Ta)O4 Ramdohrite Ag2Pb3Sb3S9 Stibiconite Sb2 O4•H2O Zinckenite PbSb2S4 Stibio-tellurobismutite (Bi,Sb)2 Te3 Falkmanite Pb3Sb2S6 Stibiodomeykite Cu3 (As,Sb) Franckeite Pb5Sn3Sb2S14 Breithauptite NiSb Stibnite Sb2 S3 Famatinite Cu3SbS4 Annivite Cu12 (Sb,Bi,As)4 S13 Stibioenargite Cu3 (As,Sb)4 Stephanite Ag5 SbS4 Gabrielite Tl6Ag3Cu6(As,Sb)9S21 Geocronite Pb5 (As,Sb)12 S8 Romeite 5CaO3•Sb2O5 Boulangerite Pb5 Sb4 S11 Cervantite Sb2O4 Cylindrite Pb3 Sn4 Sb2 S14 Dyscrasite Ag3 Sb Berthierite FeSb2 S4 Breithauptite NiSb Bournonite PbCuSbS3 Gudmundite FeSbS Kermesite Sb2 S2 O Tetrahedrite Cu12 Sb4 S13 Senarmontite Sb2 O3 Bournonite PbCuSbS3 Stenhuggarite CaFeSbAs2 O7 Andorite AgPbSb3 S6 Valentinite Sb2 O3 Jamesonite, Pb4 FeSb6 S14

Prior Art Process of Ore Extraction and Refining

At the first stage of hydrometallurgical processing of stibnite (Sb2S3), i.e. its leaching, the following acidic leaching media are commonly applied: mixture of hydrochloric and tartaric acids, mixture of nitric and tartaric acids and hot concentrated sulphuric acid. In alkaline leaching, on the other hand, the aqueous solutions of alkali metal sulphides or alkaline earth metal sulphides are considered to be the best leaching agents. Alkaline Na2S solution is the universal solvent for antimony compounds. The solubility of the majority of other metals is, however, very low except for As, Hg and Sn. It is believed that the alkaline leaching of antimony sulphide proceeds in accordance with the following reaction:

Sb2S3+3Na2S=2Na3SbS3

Flotation processes are known for concentrating minerals from their ores, typically the ore is crushed and wet ground to form a pulp and additives and frothing agents are added to the pulp in subsequent flotation steps to separate minerals from the undesired ore portions.

Flotation plants generally require large amounts of water and the availability of an adequate water supply can be a decisive factor in the selection of a site for a flotation plant. When the plant is to be located in the neighborhood of the mine and an abundant supply of good quality water cannot be conveniently hauled to the plant, it becomes necessary to utilize water available at the plant site. This available water may include so-called “mine water,” (as described in SME MINING ENGINEERING HANDBOOK, published by Society of Mining Engineers of the American Institute of Mining, Metallurgical and Petroleum Engineers, Inc. (1973) 26.2-26.6).

In some cases it becomes necessary to recirculate water from tailing ponds, thickeners and the like as described in Taggart's HANDBOOK OF ORE DRESSING, published by John Wiley & Sons, Inc. (1927), page 1276.

A considerable number of flotation plants treating sulfide ores must use water originating from mines and/or recirculated water. It is well known that sulfide mine water is usually acidic and contains high concentrations of sulfates of metals such as Fe, Mg, Ca, Na, K, Al, etc. The origin of acidity and an explanation for the occurrence of sulfate salts in mine water appear in the SME handbook. In many cases water recirculated from effluents obtained from mills handling sulfide ores is also acidic and salt-laden.

When using mine and/or recirculated plant water for sulfide flotation, selective flotation of a desired metal sulfide mineral value from other sulfides, e.g., iron sulfides, becomes difficult due to the fact that iron sulfides normally float readily in an acid medium when the familiar xanthate sulfide collectors are employed. Such acid pulps therefore limit the possibilities for selective separation of one sulfide from the other. In most cases, the desired concentrate grades can only be achieved by sacrificing the desired sulfide recovery.

One widely used remedy for such systems involves adding heavy dosages of reagents such as lime and sodium cyanide to help depress the not-to-be floated sulfides while avoiding the simultaneous depression of the to-be-floated minerals. Such reagent schedules are relatively expensive and they require great skills on the part of the operators.

Another possible remedy is to process recirculated or mine water by so-called “water treatment” in or prior to flotation. The principal methods for treating mine water and recirculated water are intended to neutralize the acidity and to remove iron. Reference is made to the SME publication. The common and most efficient water treatment makes use of lime and sodium carbonate. Even though this method is relatively frequently put to practice, it requires considerable capital expenditure for new equipment in a water treatment plant as well as additional labor to run such plant.

For low grade ore of between 5-25%, antimony is volatilized to antimony trioxide: sulfur is burned away at about 1000 degrees C. and removed as a waste gas, whereas the volatile antimony trioxide is recovered in flues, condensing pipes, a baghouse, a Cottrell precipitator or a combination of the above. Roasting and volatilization are affected almost simultaneously by heating the ore, mixed with coke or charcoal, under controlled conditions in equipment such as a shaft furnace, rotary kiln, converter or roaster. If the volatilization conditions are too oxidizing, the nonvolatile antimony tetroxide, Sb2O4 may form and the recovery of antimony, as antimony trioxide, is diminished.

The reaction may be summarized as follows:

2Sb2S3+9O2→2Sb2O3+6SO2

2Sb+1.5O2→Sb2O3

Ores having an antimony content of up to 40% are usually smelted in a blast furnace, with higher grades of the ore being reduced in a furnace at about 1200 degrees or by iron precipitation:

Sb2S3+3Fe→2Sb+3FeS

Reaction Chemistry According to the Present Specification

Stibnite, stibnite bearing ores and ore concentrates are first pre-treated by grinding and milling stibnite to a pre-determined sieve size range and directing milled stibnite powder into contact with an electrically conductive material disposed within a substantially metallic crucible operated at a pressure of between 1.5 psia to 60 psia, wherein the electrically conductive material is maintained in a molten state at a temperature range of at least 500 degrees Celsius, to yield molten antimony that is withdrawn from the metallic crucible and cast into suitable ingots.

A carbon containing reducing agent is grinded to a determined mesh size and injected into contact with the electrically conductive material and is heated by means of one or more induction coils surrounding the metallic crucible.

The reaction is summarized as follows:

Sb2O3+3CO→2Sb+3CO2

CO2+3C→6CO

In one embodiment the electrically conductive material is iron and the reaction is summarized as follows:

Sb2S3+3Fe→2Sb+3FeS

The ore is first crushed to −150 mm, and then selectively crushed and or milled to −10 mm, with final milling to a fineness of 60%—200 mesh. Herein, a minus sign in front of a coarseness measure such as “−200 mesh” or “−150 mm” means that essentially all particles are smaller than a given size, in this case 200 mesh or 150 mm. Similarly, “60%—200 mesh” means that 60% of the particles are of a size smaller than 200 mesh.

General Process Description

A process for the production of antimony from stibnite, stibnite bearing ores and ore concentrates comprising:

(a) grinding and milling stibnite, stibnite bearing ores and ore concentrates to a milled powder sieve size of at least 60%—10 mm; (b) placing milled powder into contact with an electrically conductive material melt disposed within a metallic crucible wherein electrically conductive material melt has a temperature of at least 500 degrees Celsius; (c) injecting a carbonaceous additive into contact with the electrically conductive material melt; (d) withdrawing molten antimony from metallic crucible for casting into one or more ingot mold.

The process takes place within the metallic crucible which is substantially sealed and pressurized between 1.2 psia to 60 psia.

In other embodiments, the step (a) includes grinding and milling other metal, or mineral bearing ores and ore concentrates to a milled powder sieve size of at least 60%-—10 mm;

The electrically conductive material melt is inductively heated by one or more induction coils configured to surround the metallic crucible.

It should be noted that the above process can also be applied for the refining and smelting of other types of metal ores, such as ores carrying copper, iron, aluminum, rare earth metals, etc.

Technical Background of Size Reduction:

Industrial grinding machines used in the mineral processing industries are mostly of the tumbling mill type. These mills exist in a variety of types—rod, ball, pebble autogenous and semi-autogenous. The grinding action is induced by relative motion between the particles of media—the rods, balls or pebbles. This motion can be characterized as collision with breakage induced primarily by impact or as rolling with breakage induced primarily by crushing and attrition. In autogenous grinding machines fracture of the media particles also occurs by both impact (self breakage) and attrition.

Energy Spectrum:

The energy that is required to break the material in the mill comes from the rotational energy that is supplied by the drive motor. This energy is converted to kinetic and potential energy of the grinding media. The media particles are lifted in the ascending portion of the mill and they fall and tumble over the charge causing impacts that crush the individual particles of the charge. The overall delivery of energy to sustain the breakage process is considered to be made up of a very large number of individual impact or crushing events. Each impact event is considered to deliver a finite amount of energy to the charge which in turn is distributed unequally to each particle that is in the neighborhood of the impacting media particles and which can therefore receive a fraction of the energy that is dissipated in the impact event. Not all impacts are alike. Some will be tremendously energetic such as the impact caused by a steel ball falling in free flight over several meters.

Others will result from comparatively gentle interaction between media pieces as they move relative to each other with only little relative motion. It is possible to calculate the distribution of impact energies using discrete element methods to simulate the motion of the media particles including all the many collisions in an operating mill. The distribution of impact energies is called the impact energy spectrum of the mill and this distribution function ultimately determines the kinetics of the comminution process in the mill.

In one embodiment of step (a) includes grinding and milling other metal, or mineral bearing ores and ore concentrates to a milled powder sieve size of at least 60%—10 mm;

In one embodiment of step (a) includes grinding and milling other metal, or mineral bearing ores and ore concentrates to a milled powder sieve size of at least 20%—5 mm;

In one embodiment of step (a) includes grinding and milling other metal, or mineral bearing ores and ore concentrates to a milled powder sieve size of at least 60%—1 mm;

Example of an apparatus for practicing this embodiment of the present specification:

In a non-limiting embodiment, the reactor vessel 10″ is configured with an induction coil device with a power rating of between 60 kW to 735 kW, approximately 968 volts and a metallic crucible capacity of 3200 Kg (3.2 metric tons), energy input is measured at about 660 kWh/ton, and the averaged power consumption is between 65 to 75 kWh/ton per 100 C temperature elevation.

Based on the rated efficiency of the induction coil device (less the coil IR loss averaged at 130 kWh/ton), the useful heat present in the cast iron melt is about 380 kWh/ton representing a net efficiency of about 58.5%. The temperature of the resultant syngas represents about 15% or about 98 kWh/ton of thermal energy, with the remaining losses attributable to the solid state power supply, conduction losses in the power cables, heating of the metallic material of the crucible and sensible heat present in slag material 100.

If the exergy of both the evolved syngas 80 and the cast iron melt are combined, the gross efficiency of the reactor vessel is about 72%. The reactor vessel 10″ is pressurized to a pressure of from about 1.15 bar pressure absolute to about 60 bar pressure absolute.

In an embodiment not shown here, an electrical resistance heating coil replaces the induction coil 120 of the embodiment of FIG. 14 to form additional embodiments. All variations described above can be applied, and the electrical resistance heating coil is brought into close thermal contact with the crucible 40. Thermally conductive material can be provided in the vicinity of the electrical resistance heating coil in order to improve heat transfer to the crucible 40.

In another embodiment not shown here, one or more electrical resistance coils are provided inside the hollow which is defined by the crucible 40, in order to bring the electrical resistance heating coil in close contact with the melt 90 and molten slag 100. Such electrical resistance coils can be provided together with one or more inductive coils 120 and—in a further embodiment—also together with both an electrical resistance heating coil and with one or more inductive coils 120. Cooling as described above with reference to FIG. 14 enhances the durability of the crucible 40.

Embodiments which were explained with reference to FIG. 14 can also be characterized by the following features.

The present application discloses a device for refining metals, which comprises a metallic crucible for holding an electrically conductive material, the metallic crucible further comprising a metal containing material feed opening and a metal containing material discharge opening.

At least one electric heater is provided in the vicinity of the crucible, the at least one electric heater comprises a coil for providing a flow of current through the at least one electric heater. The current flow causes melting and inductive heating of the electrically conductive material to form a molten material disposed within the metallic crucible. In particular, the molten material may comprise a molten metal layer and a slag layer.

In one embodiment, a slag conduit is provided for removing slag from slag layer and thereby adjusting the height and the composition of the slag layer. In another embodiment, the crucible is provided with a tilting an positioning mechanism in order to control the removal of slag more precisely.

A liquid cooling arrangement for the crucible is provided, such as conduits or passageways in or next to the crucible and/or an outer container containing cooling liquid, which is illustrated in FIGS. 2 and 5.

At least one feeding conduit is provided for delivering a flow stream a feed fuel into contact with the molten material. At least one exhaust conduit is provided for delivering the gas to the exterior of the crucible.

Similar to the embodiments of FIGS. 1 to 6, various cooling arrangements may be provided for a device for refining metals according to the present specification. According to a first embodiment, the liquid cooling arrangement comprises hollow passageways, which are provided within the body of the crucible, such as in FIG. 2. According to another embodiment the hollow passageways of the liquid cooling arrangement are provided within a side wall of the crucible, which is illustrated in FIG. 2 in combination with FIG. 14. According to another embodiment, which is illustrated by FIG. 2 in combination with FIG. 14, the hollow passageways of the liquid cooling arrangement are provided within a bottom wall of the crucible.

According to another embodiment, which is also shown in FIG. 2 in combination with FIG. 14, the liquid cooling arrangement comprises hollow conduits that are surrounding an outer surface of the crucible which are arranged in a series of turns or in large sections around the crucible. In FIG. 2 only a small portion of the series of turns is shown, for reasons of simplicity.

According to yet a further embodiment, which is illustrated by FIG. 5 in combination with FIG. 14, the liquid cooling arrangement comprises a hollow conduit between the crucible and an outer container which surrounds at least a part of the crucible. Such a conduit may be provided by an outer container, as is the case in FIG. 5. In particular, the outer container may surround the crucible along the bottom of the crucible and along the side walls of the crucible up to at least half of the crucible's height or at least two thirds of the crucible's height.

In one embodiment, the induction coil is surrounded by an insulating material, as is illustrated by FIGS. 3, 4 and 6 in combination with FIG. 14. In particular, the induction coil may be provided within a distance of 1 mm to 1.52 m to the side walls of the crucible, as illustrated by FIGS. 3 to 6 in combination with FIG. 14. Furthermore, the induction coil may be provided as a hollow coil, which is shown in FIGS. 3, 4 and 6.

An electric resistance coil can be brought into close thermal contact with the molten material inside the crucible and/or with the inner or even the outer surface of the crucible 40.

In another embodiment, a device is disclosed which comprises a substantially metallic crucible that encloses a hollow with a metallic surface, which may be provided by a crucible or a reactor vessel with an interior metallic surface, for holding a metallic material in the hollow. Furthermore, the metallic crucible further comprises at least one metallic material communication section, such as the inlet 53 of FIG. 14.

At least one heater, such as the induction coils of FIG. 14, can be disposed in proximity to the metallic crucible. The heater is adapted to provide inductive heating of the crucible.

A fluid cooling arrangement is disposed in proximity to the metallic crucible, which is illustrated by the cooling arrangements of FIG. 2 or FIG. 5 in combination with FIG. 14. A feeding conduit is provided which extends between the outside of the crucible and the inside of the crucible, such as the overhead lance of FIG. 14 or the feedings conduits in the bottom of the crucible of FIG. 14. Furthermore, a feeder unit, such as the 53, 54 of FIG. 14 is provided for delivering a flow stream of one or more metal-containing material into the hollow.

An exhaust conduit, the exhaust conduit extends between the inside of the crucible and the outside of the crucible. The exhaust conduit may be used to extract gas from the metal refining process, especially if the gas provides a fuel value.

In another embodiment, the present specification discloses a device with a holder unit having a metallic surface that defines a hollow for holding a molten metallic material. In particular, such a hollow may be provided by a metallic crucible or a crucible having a metallic inner surface.

A metallic material communication section is provided for charging and/or discharging a metallic material. A heater unit is disposed in proximity to the holder unit for heating the hollow. In particular, the heater unit may comprise induction coils, such as the induction coils of FIG. 14, or electrical resistance coils.

A feeder unit provides a flow stream of one or more metal-containing materials to be delivered into the hollow. Furthermore, a cooler unit is provided for cooling the holder unit, which is disposed in proximity to the holder unit, which is illustrated by the cooler units of FIGS. 2 and 5 in combination with FIG. 14.

A supply means, such as the downstream application conduit of FIG. 14, is provided for delivering a gas from inside the crucible to the outside of the crucible.

According to another embodiment which may be realized with a device according to FIG. 14, the current specification discloses a metal refining method for refining a metal containing material. An electrically conductive material is placed within a metallic crucible. The electrically conductive material is inductively heated to form a molten material disposed within the metallic crucible and maintaining the molten material in a molten state. At least a portion, for example a metallic inner surface, of the crucible is cooled with a cooling liquid.

A flow stream of one or more nonmetallic feed fuel, such as for example a hydrocarbon-containing feed fuel, oxidizing gases, flue gas etc. is delivered into contact with the molten material. Thereby at least a portion of the non-metallic feed fuel is converted to syngas.

The metal containing material is delivered into contact with the molten material and thereby converting the metal containing material into a refined metal containing material. The refined metal containing material is extracted from the crucible via a discharge channel or via a discharge opening, which may involve tilting of the crucible. For extraction of the refined metal containing material, the slag channel 110 of FIG. 14 may be used or another conduit which is provided for that purpose. Alternatively, the refined metal containing material may also be extracted through the central opening of the crucible through which the crucible is charged with material from above.

Furthermore, syngas is extracted from the crucible. In one embodiment, the syngas extraction takes place during the metal refining process. The extraction may take place essentially without interruptions, at pre-determined intervals or at pre-determined times.

In one embodiment, the step of cooling at least a portion of the crucible, or a metallic inner surface of the crucible, comprises passing a stream of the cooling liquid through the body of the crucible. According to another embodiment the step of cooling at least a portion of the crucible, or a metallic inner surface of the crucible, comprises passing a stream of the cooling liquid in proximity to an outer surface of the crucible, wherein the stream may be passed through the body of the crucible or in proximity to the crucible.

According to a further embodiment, the devices comprise controlling an input, output or intermediate temperature of the cooling liquid to lie within a predetermined temperature range such as −37° C. to 35° C., 5° C. to 55° C., 3° C. to 110° C.

In particular, the step of cooling at least a portion of the crucible, or a metallic inner surface may comprise recirculating the cooling liquid. In a further embodiment, the metal refining method, the step of circulating the fluid comprises evaporating the liquid, condensing the evaporated fluid and recirculating the condensed liquid.

According to yet another embodiment, a metal refining method for refining a metal containing material comprises steps of placing a metallic material within a hollow such that it is in contact with a metallic surface of the hollow. The metallic material is melted to form a molten metallic material and the molten metallic material is maintained in a molten state.

The metallic surface is cooled with a fluid and a flow stream of a non-metallic material, for example a hydrocarbon-containing material, oxidizing gases, flue gas etc., is brought into contact with the molten metallic material.

The metal containing material is delivered into contact with the molten material and thereby converting the metal containing material into a refined metal containing material. The refined metal containing material is extracted from the hollow, and the reaction gas is extracted from the hollow. The non-metallic material represents a feed fuel, such as carbon, rubber, wood pellets or other fuels mentioned in the present specification.

FIGS. 15 and 16 show various communication means between a gasifier and a hydrocarbon processing plant. By way of example, FIGS. 15 and 16 show the atmospheric distillation tower 1201 of FIGS. 5 and 6. However, the embodiments of FIG. 15 are not limited to a specific type of hydrocarbon processing plant. The various means for transporting energy and/or material between the gasifier 10 and the distillation tower 1201 shown in FIGS. 15 and 16 can be used individually or also in combination.

A first process heater 603, which comprises a burner 608 and a heat exchanger 609, is provided between the downstream application conduit 140 of the gasifier 10 and a receiving portion 1202 of the atmospheric distillation column 1201. A second process heater 607, which comprises a burner 610 and a heat exchanger 611 is provided between an outlet 1204 of a portion 1203 of the atmospheric distillation column 1201 and the overhead lance conduit 52 of the gasifier 10.

FIG. 16 shows units for material exchange, information exchange and electric energy exchange between a gasifier 10 and atmospheric distillation column 1201.

A syngas conduit 1205 is provided between the downstream application conduit 140 of the gasifier 10 and an inlet 1206 of a portion of the atmospheric distillation column 1201. Similarly, a discharge material conduit 1207 is provided between an outlet 1208 of a second portion of the atmospheric distillation column 1201 and the overhead lance conduit 52 of the gasifier 10.

A first generator 1209 is connected to the downstream application conduit 140, for example by means of a gas turbine and an output of the first generator 1209 is connected to an electric appliance at the distillation column 1201, which is not shown in FIG. 16, such as a heater, a stirrer, a pump, an electric furnace etc. Similarly, a second generator 1210 is connected to the discharge conduit 1207 of the distillation column 1201, for example by means of a gas turbine. An output of the second generator 1210 is connected to the induction coil apparatus of the gasifier 10.

An output of a first sensor 1211 at the gasifier 10 is connected to a first process controller 1212 of the distillation column 1201. The first process controller 1212 is in turn connected to controllable parts of the distillation column, such as heaters, coolers, valves, stirrers, pumps, etc., which are not shown in FIG. 16. Similarly, an output of a second sensor 1213 at the distillation column 1201 is connected to a second process controller 1214, which is in turn connected to controllable parts of the gasifier, such as heaters, coolers, valves, stirrers, pumps, the power supply to the induction coil, etc., which are not shown in FIG. 16.

FIG. 17 shows an exemplary embodiment of a crude oil distillation unit (CDU) 1000″ comprising the atmospheric distillation column 1201 of FIG. 16, wherein appliances of the CDU 1000″ are powered by syngas from the gasifier 10 of FIG. 16. In FIG. 17, electrical connections to the generator 1209 are symbolized by small open circles.

The CDU 1000″ comprises a side stripper 1215 that is connected to the atmospheric distillation column 1201 and extraction pumps 1216 that are connected to the side stripper 1215. In one embodiment, the outlet 1204 of FIG. 15 or the outlet 1208 of FIG. 16 corresponds to an output conduit that is connected to one or more of the extraction pumps 1216. In another embodiment, the outlet 1204 or the outlet 1208 corresponds to a side draw-off that is connected to a tray of the atmospheric distillation column 1201.

A pump around pump 1217 is connected between different trays of the atmospheric distillation column 1201. A residue pump 1218 is connected to the bottom of the atmospheric distillation column 1201. A recirculation pump 1219 is connected to a reflux drum and an upper part of the atmospheric distillation column 1201. A further pump 1220 is connected to a crude oil inlet. The pumps 1216-1220 are electrically connected to the generator 1209.

The generator 1209 is connected to an output shaft of a syngas fired turbine 1221 which is connected to the downstream application conduit 140 of the gasifier 10.

The CDU 1000″ comprises various heat exchangers for delivering the heat of the product streams and the pump around stream to the crude oil input stream. Furthermore, the CDU 1000″ comprises a heat exchanger 1222 between a process fluid input conduit and an overhead output conduit of the atmospheric distillation column 1201. An air cooled condenser 1223, which is powered by the generator 1209, is connected between the heat exchanger 1222 and the reflux drum.

Similar to the CDUs of FIGS. 7 and 8, the CDU 1000′ comprises means for desalinating the crude oil input stream and a fired heater for preheating the crude oil input stream to an input temperature of approximately 398° C. Furthermore, an electric heater, which is powered by the generator 1209 and which is not shown in FIG. 17, is provided for preheating the crude oil input stream.

The embodiments of the present specification can also be described with the following lists of elements being organized into items. The respective combinations of features which are disclosed in the item list are regarded as independent subject matter, respectively, that can also be combined with other features of the application.

-   1. A gasifier for converting one or more feed fuel to synthesis gas,     comprising: a substantially metallic crucible for holding an     electrically conductive material; at least one induction coil     disposed in proximity to the bottom of the metallic crucible and     providing a flow of current through the at least one induction coil     so as to generate a magnetic field to induce an eddy current in the     metallic crucible, in the electrically conductive material, or in a     combination thereof, and to cause melting and heating of the     electrically conductive material to form a molten material disposed     within the metallic crucible, at least one conduit for providing a     flow stream of one or more feed fuel to be delivered into contact     with the molten material to convert at least a portion of one or     more feed fuel to synthesis gas, at least one pipeline apparatus for     delivering the synthesis gas for subsequent conversion to electrical     power, mechanical shaft power, one or more Fischer-Tropsch products,     carbon dioxide, hydrogen, derivatives thereof, or combinations     thereof. -   2. The gasifier of item 1 wherein the at least one induction coil is     electrically insulated from contact with the metallic crucible by     having an electrically insulating material interposed between the     metallic crucible and the at least one induction coil. -   3. A gasification method for converting one or more feed fuel to     synthesis gas, comprising the steps of: placing an electrically     conductive material within a metallic crucible; surrounding the     metallic crucible with at least one induction coil wherein the at     least one induction coil is provided with alternating current to     generate a magnetic field to cause a magnetic coupling to the     electrically conductive material, to the metallic crucible, or to a     combination thereof to inductively melt and heat the electrically     conductive material to form a molten material disposed within the     metallic crucible; directing one or more flow stream of one or more     feed fuel to be delivered into contact with the molten material to     convert at least a portion of one or more feed fuel to synthesis     gas. -   4. The method of item 3 wherein the metallic crucible is     electrically insulated from the at least one induction coil by     placing an electrically insulating material interposed between the     metallic crucible and the at least one induction coil. -   5. The method of item 3 wherein at least a portion of the synthesis     gas is converted to electrical power, mechanical shaft power, one or     more Fischer-Tropsch products, carbon dioxide, hydrogen, derivatives     thereof, or combinations thereof. -   6. The method of item 3 wherein a frequency of the alternating     current provided to the at least one induction coil is adjusted to a     predetermined value to electromagnetically stir the molten material     disposed within the metallic crucible. -   7. A smelter furnace for melting and or heating electrically     conductive material and refining of metals, comprising a metallic     crucible for holding an electrically conductive material; one or     more induction coil positioned in proximity and surrounding the     metallic crucible; an electrically insulating material interposed     between the metallic crucible and the one or more induction coil to     cause electrical insulation between the metallic crucible and the     one or more induction coil; a power supply device for providing     alternating current to the one or more induction coil to generate a     magnetic field to cause magnetic coupling to the electrically     conductive material, to the metallic crucible, or to a combination     thereof and to cause an eddy current for inductively melting and or     heating the electrically conduction material, wherein the metallic     crucible is configured with a substantially cylindrical geometry and     the power supply device is further configured to adjust the     frequency of the alternating current to one or more predetermined     frequency. -   8. The smelter furnace of item 7 wherein at least a part of the     metallic crucible is formed into a channel to allow for withdrawal     of melted electrically conductive material, molten refined metal,     molten slag or a combination thereof, to be withdrawn when the     metallic crucible is tilted into a desired withdrawal orientation     and at least a part of induction furnace is adapted with one or more     conduits for delivering crushed sulfide minerals, nonsulfide     minerals, metal ores, metal oxides, silicates, or a combination     thereof, into contact with the melted electrically conductive     material to recover molten refined metal from the crushed sulfide     minerals, the nonsulfide minerals, the metal ores, the metal oxides,     the silicates, or the combination thereof. -   9. The smelter furnace of item 7 wherein a material of the metallic     crucible is selected from copper, steel, Inconel, iron, tungsten,     titanium, molybdenum, or alloy derivatives thereof, or combinations     thereof. -   10. A gasification method for converting one or more feed fuel to     synthesis gas, comprising the steps of: placing an electrically     conductive material within a metallic crucible; surrounding the     metallic crucible with one or more induction coil; placing an     electrically insulating material interposed between the metallic     crucible and the at least one induction coil to cause the metallic     crucible to be electrically insulated from the at least one     induction coil; controlling the length of the space gap between the     exterior wall surface of metallic crucible and the inner wall     surface of at least one induction coil to be less than or equal to 1     inch; energizing at least one induction coil by providing at least     one induction coil with alternating current to generate a magnetic     field to cause magnetic coupling to the electrically conductive     material, to the metallic crucible, or to a combination thereof to     inductively melt and heat the electrically conductive material to     form a molten material disposed within the metallic crucible;     heating and maintaining the molten material disposed within the     metallic crucible to a temperature of at least 1000 degrees Celsius;     directing one or more flow stream of one or more feed fuel to be     delivered into contact with the molten material to convert at least     a portion of the one or more feed fuel to synthesis gas and     dissolving at least a portion of carbon present in one or more feed     fuel into molten material; controlling the carbon equivalent (CE)     content dissolved within the molten material to a range between 0.5     to 5.6 mass weight percent; collecting at least a portion of the     synthesis gas for conversion to electrical power, to mechanical     shaft power, to one or more Fischer-Tropsch products, carbon     dioxide, hydrogen, derivatives thereof, or to combinations thereof. -   11. The method of item 10 wherein the frequency of alternating     current provided to the at least one induction coil is adjusted to a     predetermined value to electromagnetically stir the molten material     disposed within the metallic crucible. -   12. The method of item 10 wherein the metallic crucible is formed     from a metal selected from copper, steel, Inconel, iron, tungsten,     titanium, molybdenum, or alloy derivatives thereof, or combinations     thereof. -   13. The method of item 10 wherein the electrically insulating     material has a maximum continuous service temperature of at least     1200 degrees Celsius and a material thickness of at least 1     millimeter. -   14. The method of item 3 wherein the metallic crucible is formed by     machining one or more metal selected from copper, steel, Inconel,     iron, tungsten, titanium, molybdenum, or alloy derivatives thereof,     or combinations thereof. -   15. The method of item 3 wherein the metallic crucible is formed by     sintering one or more metal selected from copper, steel, Inconel,     iron, tungsten, titanium, molybdenum, or alloy derivatives thereof,     or combinations thereof. -   16. The method of item 3 wherein the metallic crucible is formed by     one or more metallurgical casting steps, an wherein a material of     the metallic crucible is selected from copper, steel, Inconel, iron,     tungsten, titanium, molybdenum, or alloy derivatives thereof, or     combinations thereof. -   17. The method of item 3 wherein the metallic crucible is formed by     one or more metallurgical forging steps, and wherein a material of     the metallic crucible is selected from copper, steel, Inconel, iron,     tungsten, titanium, molybdenum, or alloy derivatives thereof, or     combinations thereof. -   18. A gasification method for converting at least a portion of a     flue gas exhaust stream to synthesis gas, comprising the steps of:     -   a) capturing at least a portion of the flue gas exhaust stream;     -   b) accumulating the captured flue gas exhaust from the step of         a);     -   c) withdrawing at least a portion of the accumulated captured         flue gas from the step of b) and generating a pressurized stream         of pressurized flue gas;     -   d) directing at least a portion of the pressurized flue gas from         the step of c) into contact with one or more body of molten         metal disposed within one or more crucible, wherein the flow         pressure of pressurized flue gas from the step of c) is greater         than the hydrostatic pressure of one or more body of molten         metal;     -   e) collecting at least a portion of the synthesis gas from the         one or more crucible for conversion to electrical power,         mechanical shaft power, one or more Fischer-Tropsch products,         carbon dioxide, hydrogen, derivatives thereof, or combinations         thereof. -   19. A gasification method for converting one or more feed fuel to     synthesis gas, comprising the steps of: placing an electrically     conductive material within a metallic crucible; surrounding the     metallic crucible with one or more induction coil wherein at least     one induction coil is provided with alternating current to generate     a magnetic field to cause magnetic coupling to the electrically     conductive material, to the metallic crucible, or to a combination     thereof to inductively melt and heat electrically conductive     material to form a molten material disposed within the metallic     crucible; directing one or more flow stream of one or more feed fuel     to be delivered into contact with the molten material to convert at     least a portion of the one or more feed fuel to synthesis gas. -   20. The gasification method of item 19 wherein at least a portion of     the one or more feed fuel is a captured flue gas exhaust stream that     is pressurized to a predetermined flow pressure and is directed into     contact with the molten material from below the surface of the     molten material, and at least a portion of the synthesis gas is     converted to electrical power, mechanical shaft power, one or more     Fischer-Tropsch products, carbon dioxide, hydrogen, derivatives     thereof, or combinations thereof. -   21. A process for crude oil distillation into a plurality of     hydrocarbon fraction products, comprising;     -   a furnace reactor for reacting a feed to form a fuel gas         containing CO and hydrogen by contacting the feed into a melt         disposed within the furnace reactor; and the furnace reactor         generating heat by reacting fuel gas with air to form a flue gas         containing carbon dioxide, directing at least a portion of the         heat generated by furnace reactor into a fractional distillation         tower supplied with a fluid flow of crude oil to cause thermal         distillation of a pre-heated fluid flow of crude oil into said         plurality of hydrocarbon fraction products wherein the fluid         flow of crude oil is pre-heated to a predetermined temperature         by heat exchange between the fluid flow of crude oil and the         flue gas to derive a pre-heated fluid flow of crude oil wherein         there is essentially no fluid contact between the fluid flow of         crude oil and the flue gas. -   22. The process of item 21 wherein the feed reacts with a controlled     and determined quantity of air from below the surface of the melt to     dissolve carbon and sulphur from the feed into the melt to form the     fuel gas. -   23. The process of item 21 wherein the fuel gas comprises carbon     dioxide and wherein the fuel gas reacts with a controlled jet of air     from above the surface of the melt in a predetermined stoichiometric     quantity to cause combustion and formation of the flue gas to     generate heat. -   24. The process of item 21 wherein at least a portion of the flue     gas formed is directed to circulate in at least one heat exchanger     device to cause heat to be transferred from the flue gas to the     fluid flow of crude oil to derive the pre-heated fluid flow of crude     oil for thermal distillation of the pre-heated fluid flow of crude     oil into plurality of hydrocarbon fraction products. -   25. The process of item 21 wherein the plurality of hydrocarbon     fraction products is selected from naphtha, kerosene, diesel, gas     oil, gasoline, paraffin wax, heavy fuel oil, liquefied petroleum     gas, jet fuel, asphalt, petroleum coke, or a combination thereof. -   26. The process of item 21 wherein the melt is selected from a     molten metal, a molten iron alloy, or a combination thereof. -   27. A process for thermal distillation and or cracking of     hydrocarbons into refined hydrocarbon products; comprising     -   operating a thermal distillation and or cracking unit         comprising 1) at least one heat producing furnace for producing         heat, 2) at least one heat exchanger device having a radiant         section, a convection section, or a combination thereof,     -   3) passing a process fluid stream comprising hydrocarbons         through at least one heat exchanger device and 4) directing at         least a portion of heat produced from the at least one heat         producing furnace into operational communication with the at         least one heat exchanger device,     -   5) receiving and discharging from one or more outlet of the at         least one heat exchanger device one or more refined hydrocarbon         products, wherein the at least one heat producing furnace is         configured with the one or more crucible having a melt disposed         therein and at least one predetermined feed fuel is supplied and         delivered into fluid communication with the melt to cause         formation of a stream of synthesis gas, the synthesis gas being         directed into one or more synthesis gas burner to initiate         combustion of the synthesis gas with an oxidant gas to produce         heat. -   28. A hydrocarbon conversion process, comprising: passing a     hydrocarbon stream through the at least one heater comprising at     least one syngas-fired burner for producing heat, a radiant section     having at least one radiant section tube, and a convection section     having at least one convection section tube in fluid communication     with the at least one radiant section tube, wherein,     -   (i) the at least one heater is in fluid communication with the         at least one gasifier having a melt disposed therein;     -   (ii) the at least one conduit device for introducing one or more         feed fuel material into contact with melt disposed within the at         least one gasifier to generate syngas, and     -   (iii) the at least one gas flow channel is provided for         delivering syngas generated from the at least one gasifier to         the at least one syngas-fired burner for producing heat by         combustion of syngas with an oxidant gas. -   29. The hydrocarbon conversion process according to item 28, wherein     the hydrocarbon conversion process comprises reforming, alkylating,     dealkylating, hydrogenating, hydrotreating, dehydrogenating,     isomerizing, dehydroisomerizing, dehydrocyclizing, cracking, or     hydrocracking. -   30. A crude oil refinery plant; comprising     -   At least one reactor unit having one or more crucible for         holding one or more electrically conductive material within one         or more crucible;     -   One or more induction coil surrounding one or more crucible to         melt electrically conductive material into one or more melt and         one or more conduit apparatus for delivering one or more feed         material into contact with the one or more melt to dissolve         carbon present in one or more feed material into the one or more         melt and to generate synthesis gas;     -   directing the synthesis gas to one or more combustion device to         generate heat in the one or more heat exchanger units in fluid         communication with at least one crude distillation unit (CDU),         process heater, steam generator, or a combination thereof,         wherein a temperature of the one or more melt is at least 1000         degrees Celsius. -   31. Processing plant comprising     -   a gasifier device comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             one or more feed fuel to be delivered into contact with the             molten material to convert at least a portion of the one or             more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   a heat extraction unit for providing heat energy from the         gasifier device to the hydrocarbon processing plant, the heat         extraction unit being in fluid communication with the supply         conduit, the heat extraction unit further comprising a heat         exchanger, wherein the heat exchanger is in thermal contact with         at least one section of the hydrocarbon processing plant. -   32. Processing plant according to item 31, wherein the heat     extraction unit comprises a burner, an inlet section of the burner     being connected to the supply conduit. -   33. Processing plant comprising     -   a gasifier device comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             one or more feed fuel to be delivered into contact with the             molten material to convert at least a portion of the one or             more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   a discharge material conduit extending between a discharge         section of the hydrocarbon processing plant and a feeding         conduit of the crucible. -   34. Processing plant according to item 33, wherein the discharge     material conduit comprises a unidirectional feed element providing     essentially a one-way flow of discharge material from the     hydrocarbon processing plant to the feeding conduit of the crucible. -   35. Processing plant comprising     -   a gasifier device comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             one or more feed fuel to be delivered into contact with the             molten material to convert at least a portion of the one or             more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible, the processing plant further             comprising         -   a hydrocarbon processing plant for processing a hydrocarbon             based process fluid,         -   a heat extraction unit for providing heat energy from the             hydrocarbon processing plant to the gasifier device, the             heat extraction being in fluid communication with at least             one section of the hydrocarbon processing plant, the heat             extraction unit further comprising a heat exchanger, wherein             the heat exchanger is in thermal contact with at least one             section of the gasifier device. -   36. Processing plant comprising     -   a gasifier device comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             one or more feed fuel to be delivered into contact with the             molten material to convert at least a portion of the one or             more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible.     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   a sensor, the sensor being in contact with an area of the         hydrocarbon processing plant and providing a sensor signal,     -   a process control means for controlling the gasifier device in         response to the sensor signal. -   37. Processing plant comprising     -   a gasifier device comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             one or more feed fuel to be delivered into contact with the             molten material to convert at least a portion of the one or             more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   a sensor being in contact with an area of the gasifier device         and providing a sensor signal,     -   a process control means for controlling the hydrocarbon         processing plant in response to the sensor signal. -   38. Processing plant comprising     -   a device for converting one or more feed fuel to syngas, the         device for converting the one or more feed fuel to syngas         comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             the one or more feed fuel to be delivered into contact with             the molten material to convert at least a portion of the one             or more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   wherein the device for converting the one or more feed fuel to         syngas further comprises a generator unit for providing electric         energy to the hydrocarbon processing plant. -   39. Processing plant according to item 38, wherein the generator     unit uses heat energy from the device for converting the one or more     feed fuel to syngas for providing electric energy. -   40. Processing plant according to item 38, wherein the generator     unit uses syngas from the device for converting the one or more feed     fuel to syngas for providing electric energy. -   41. Processing plant comprising     -   a device for converting one or more feed fuel to syngas, the         device for converting the one or more feed fuel to syngas         comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             the one or more feed fuel to be delivered into contact with             the molten material to convert at least a portion of the one             or more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   a generator unit for providing electric energy to the device for         converting the one or more feed fuel to syngas. -   42. Processing plant according to item 41, wherein the generator     unit uses heat energy from the hydrocarbon processing plant for     providing electric energy. -   43. Processing plant according to item 41, wherein the generator     unit uses fuel material stream from the hydrocarbon processing plant     for providing electric energy. -   44. Processing plant comprising     -   a device for converting one or more feed fuel to syngas, the         device for converting the one or more feed fuel to syngas         comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             the one or more feed fuel to be delivered into contact with             the molten material to convert at least a portion of the one             or more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   a syngas conduit extending between the supply conduit and a         receiving section of the hydrocarbon processing plant. -   45. Processing plant comprising     -   a device for converting one or more feed fuel to syngas, the         device for converting the one or more feed fuel to syngas         comprising         -   a substantially metallic crucible which encloses a hollow             with a metallic surface for holding a metallic material in             the hollow;         -   at least one heater, the at least one heater being disposed             in proximity to the metallic crucible, and the at least one             heater being adapted to provide inductive and/or resistance             heating of the crucible.         -   a fluid cooling arrangement disposed in proximity to the             metallic crucible.         -   at least one feeding conduit, the feeding conduit extending             between the outside of the crucible and the inside of the             crucible.         -   at least one supply conduit, the supply conduit extending             between the inside of the crucible and the outside of the             crucible.     -   the processing plant further comprising     -   a hydrocarbon processing plant for processing a hydrocarbon         based process fluid,     -   wherein the hydrocarbon processing plant is in communication         with the device for converting the one or more feed fuel to         syngas. -   46. Processing plant comprising     -   a holder unit that defines a hollow for holding a molten         metallic material,     -   at least one heater unit disposed in proximity to the holder for         heating the hollow,     -   at least one feeder unit for providing a flow stream of one or         more combustible material to be delivered into the hollow,     -   a cooler unit for cooling the holder, the cooler unit being         disposed in proximity to the holder unit,     -   at least one supply conduit for supplying an output gas stream         from the hollow to the exterior of the holder unit,     -   a hydrocarbon processing plant for processing hydrocarbon based         polymers,     -   communication means for providing communication between a holder         interface of the holder unit and a plant interface of the         hydrocarbon processing plant. -   47. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible,     -   transferring heat energy from the extracted syngas to the         hydrocarbon based process fluid. -   48. A method of processing a hydrocarbon based process fluid     according to item 47, comprising combusting the extracted syngas and     transferring the combustion heat to the hydrocarbon based process     fluid. -   49. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more fraction of a         hydrocarbon based process fluid into contact with the molten         material, thereby converting at least a portion of one or more         feed fuel to syngas     -   extracting the syngas from the crucible,     -   transferring a portion of the hydrocarbon based process fluid to         the molten material. -   50. A method of processing a hydrocarbon based process fluid     according to item 49, wherein the flow stream of one or more     fraction of a hydrocarbon based process fluid is essentially a     one-way flow stream. -   51. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible,     -   transferring heat energy from the hydrocarbon based process         fluid to the flow stream of the one or more feed fuel. -   52. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible,     -   measuring a process value of the hydrocarbon based process         fluid, and controlling the conversion of the one or more feed         fuel to syngas in response to the sensor signal. -   53. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible,     -   measuring a process value of the conversion of at east a portion         of the one or more feed fuel to syngas,     -   controlling the processing of the hydrocarbon based process         fluid in response to the sensor signal. -   54. A method of processing a hydrocarbon based process fluid using     electrical energy, comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas,     -   extracting the syngas from the crucible,     -   generating electric energy from the syngas,     -   using the generated electric energy for the processing of the         hydrocarbon based process fluid. -   55. Method according to item 54, comprising extracting heat energy     from the syngas for the generation of the electric energy. -   56. Method according to item 54, comprising     -   combusting the syngas,     -   generating the electric energy from the combustion of the         syngas. -   57. A method of processing a hydrocarbon based process fluid using     electrical energy, comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible,     -   generating electric energy from the hydrocarbon based process         fluid,     -   using the generated electric energy for the conversion of the         one or more feed fuel to syngas. -   58. Method according to item 57, comprising extracting heat energy     from the hydrocarbon based process fluid for the generation of the     electric energy. -   59. Method according to item 57, comprising     -   combusting a portion/residue of the hydrocarbon based process         fluid,     -   generating the electric energy from the combustion of the         hydrocarbon based process fluid. -   60. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more feed fuel into contact         with the molten material, thereby converting at least a portion         of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible,     -   transferring at least a portion of the syngas to the hydrocarbon         based process fluid. -   61. A method of processing a hydrocarbon based process fluid,     comprising:     -   placing a metallic material within a hollow such that it is in         contact with a metallic surface of the hollow;     -   melting the metallic material to form a molten metallic material         and maintaining the molten metallic material in a molten state;     -   cooling the metallic surface with a fluid;     -   bringing one or more flow stream of one or more         hydrocarbon-containing material into contact with the molten         metallic material;     -   extracting reaction gas from the hollow,     -   establishing a communication between the hollow and the         hydrocarbon based process fluid. -   62. Processing plant comprising     -   a device for converting one or more feed fuel to syngas, the         device for converting the one or more feed fuel to syngas         comprising         -   a crucible for holding a metallic material,         -   at least one electric induction and/or resistance heater in             the vicinity of the crucible, the at least one electric             induction and/or resistance heater being provided for             melting and inductive and/or resistance heating of the             metallic material to form a molten material disposed within             the crucible,         -   at least one feeding conduit for providing a flow stream of             the one or more feed fuel to be delivered into contact with             the molten material to convert at least a portion of the one             or more feed fuel to syngas,         -   a liquid cooling arrangement for the crucible,         -   at least one supply conduit for delivering the syngas to the             exterior of the crucible,     -   the processing plant further comprising     -   a flue gas accumulator plant for processing a flue gas,     -   a flue gas discharge conduit extending between a discharge         section of the flue gas accumulator plant and a feeding conduit         of the crucible. -   63. Processing plant according to item 62, wherein the flue gas     discharge conduit comprises a unidirectional feed element providing     essentially a one-way flow of discharge material from the flue gas     accumulator plant to the feeding conduit of the crucible. -   64. Processing plant comprising     -   a device for converting one or more feed fuel to syngas, the         device for converting the one or more feed fuel to syngas         comprising         -   a substantially metallic crucible which encloses a hollow             with a metallic surface for holding a metallic material in             the hollow;         -   at least one heater, the at least one heater being disposed             in proximity to the metallic crucible, and the at least one             heater being adapted to provide inductive and/or resistance             heating of the crucible,         -   a fluid cooling arrangement disposed in proximity to the             metallic crucible,         -   at least one feeding conduit, the feeding conduit extending             between the outside of the crucible and the inside of the             crucible,         -   at least one supply conduit, the supply conduit extending             between the inside of the crucible and the outside of the             crucible.

the processing plant further comprising

-   -   a flue gas accumulator unit and a flue gas discharge conduit         extending between a discharge section of the flue gas         accumulator unit and a feeding conduit of the crucible.

-   65. Processing plant comprising     -   a holder unit that defines a hollow for holding a molten         metallic material,     -   at least one heater unit disposed in proximity to the holder for         heating the hollow,     -   at least one feeder unit for providing a flow stream of one or         more combustible material to be delivered into the hollow,     -   a cooler unit for cooling the holder, the cooler unit being         disposed in proximity to the holder unit,     -   at least one supply conduit for supplying an output gas stream         from the hollow to the exterior of the holder unit,     -   a flue gas accumulator unit for processing flue gas,     -   communication means for providing communication between a holder         interface of the holder unit and a flue gas accumulator         interface of the flue gas accumulator unit.

-   66. A gasification method for converting one or more feed fuel to     syngas     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   storing flue gas from a combustion process in a flue gas storage         plant;     -   withdrawing the stored flue gas from the flue gas storage plant         and delivering the flue gas into contact with the molten         material, thereby converting at least a portion of the flue gas         to syngas;     -   extracting syngas from the crucible.

-   67. A method according to item 66, comprising delivering one or more     additional feed fuel into contact with the molten material, thereby     converting at least a portion of the one or more additional feed     fuel to syngas.

-   68. A method comprising:     -   placing a metallic material within a hollow such that it is in         contact with a metallic surface of the hollow;     -   melting the metallic material to form a molten metallic material         and maintaining the molten metallic material in a molten state;     -   cooling the metallic surface with a fluid;     -   delivering flue gas from a combustion process into contact with         the molten material;     -   extracting reaction gas from the hollow.

-   69. A device for refining metals, comprising:     -   a metallic crucible for holding an electrically conductive         material, the metallic crucible further comprising a metal         containing material feed opening and a metal containing material         discharge opening,     -   at least one electric induction and/or resistance heater in the         vicinity of the crucible, the at least one electric induction         and/or resistance heater comprising an induction coil for         providing a flow of current through the at least one electric         induction and/or resistance heater so as to cause melting and         inductive and/or resistance heating of the electrically         conductive material to form a molten material disposed within         the metallic crucible,     -   a liquid cooling arrangement for the crucible,     -   at least one feeding conduit for providing a flow stream of one         or more feed fuel to be delivered into contact with the molten         material.     -   at least one exhaust conduit for delivering the gas to the         exterior of the crucible.

-   70. Device according to item 69, wherein the liquid cooling     arrangement comprises passageways, the passageways being provided     within the body of the crucible.

-   71. Device according to item 70, wherein the passageways of the     liquid cooling arrangement are provided within a side wall of the     crucible.

-   72. Device according to item 70 or item 71, wherein the passageways     of the liquid cooling arrangement are provided within a bottom wall     of the crucible.

-   73. Device according to one of the items 69 to 72, the liquid     cooling arrangement comprising hollow conduits, the hollow conduits     surrounding an outer surface of the crucible.

-   74. Device according to one of the items 69 to 73, the liquid     cooling arrangement comprising at least one hollow conduit between     the crucible and an outer container which surrounds at least a part     of the crucible.

-   75. Device according to item 74, wherein the hollow conduit is     provided by an outer container which surrounds the crucible along     the bottom of the crucible and along the side walls of the crucible     up to at least half of the crucible's height.

-   76. Device according to one of the items 69 to 75, wherein the     induction coil is surrounded by an insulating material.

-   77. Device according to one of the items 69 to 76, wherein the     induction coil is provided within a distance of 1 mm to 1.52 m to     the side walls of the crucible.

-   78. Device according to one of the items 69 to 77, wherein the     induction coil is a hollow coil.

-   79. A device comprising:     -   a substantially metallic crucible which encloses a hollow with a         metallic surface for holding a metallic material in the hollow,         the metallic crucible further comprising at least one metallic         material communication section,     -   at least one heater, the at least one heater being disposed in         proximity to the metallic crucible, and the at least one heater         being adapted to provide inductive and/or resistance heating of         the crucible,     -   a fluid cooling arrangement disposed in proximity to the         metallic crucible,     -   at least one feeding conduit, the feeding conduit extending         between the outside of the crucible and the inside of the         crucible,     -   at least one feeder unit for providing a flow stream of one or         more metal-containing material to be delivered into the hollow,     -   at least one exhaust conduit, the exhaust conduit extending         between the inside of the crucible and the outside of the         crucible.

-   80. A device, comprising:     -   a holder unit with a metallic surface that defines a hollow for         holding a molten metallic material, the hollow providing at         least one metallic material communication section,     -   at least one heater unit disposed in proximity to the holder         unit for heating the hollow,     -   at least one feeder unit for providing a flow stream of one or         more metal-containing materials to be delivered into the hollow,     -   a cooler unit for cooling the holder unit, the cooler unit being         disposed in proximity to the holder unit,     -   at least one supply means for delivering a gas from inside the         crucible to the outside of the crucible.

-   81. A metal refining method for refining a metal containing     material,     -   placing an electrically conductive material within a metallic         crucible;     -   inductively heating the electrically conductive material to form         a molten material disposed within the metallic crucible and         maintaining the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of one or more non-metallic feed fuel         into contact with the molten material, thereby converting at         least a portion of the one or more non-metallic feed fuel to         syngas;     -   delivering the metal containing material into contact with the         molten material and thereby converting the metal containing         material into a refined metal containing material;     -   extracting the refined metal containing material from the         crucible;     -   extracting the syngas from the crucible.

-   82. Metal refining method according to item 81, wherein the step of     cooling at least a portion of the crucible comprises passing a     stream of the cooling liquid through the body of the crucible.

-   83. Metal refining method according to item 81 or item 82, wherein     the step of cooling at least a portion of the crucible comprises     passing a stream of the cooling liquid in proximity of an outer     surface of the crucible.

-   84. Metal refining method according to one of items 81 to 83,     comprising controlling a temperature of the cooling liquid to lie     within a predetermined temperature range.

-   85. Metal refining method according to one of the items 81 to 84,     wherein the step of cooling at least a portion of the crucible     comprises circulating the cooling liquid.

-   86. Metal refining method according to item 85, wherein the step of     circulating the fluid comprises evaporating the liquid, condensing     the evaporated fluid and recirculating the condensed liquid.

-   87. A metal refining method for refining a metal containing material     comprising the steps of:     -   placing a metallic material within a hollow such that it is in         contact with a metallic surface of the hollow;     -   melting the metallic material to form a molten metallic material         and maintaining the molten metallic material in a molten state;     -   cooling the metallic surface with a fluid;     -   bringing one or more flow stream of one or more non-metallic         material into contact with the molten metallic material;     -   delivering the metal containing material into contact with the         molten material and thereby converting the metal containing         material into a refined metal containing material;     -   extracting the refined metal containing material from the         hollow;     -   extracting reaction gas from the hollow.

-   101. A device for converting one or more feed fuel to syngas,     comprising:     -   a metallic crucible for holding an electrically conductive         material;     -   at least one electric heater in the vicinity of the crucible,         the at least one electric heater comprising a coil for providing         a flow of current through the at least one electric heater so as         to cause melting and heating of the electrically conductive         material to form a molten material disposed within the metallic         crucible,     -   a liquid cooling arrangement for the crucible,     -   at least one feeding conduit for providing a flow stream of the         one or more feed fuel to be delivered into contact with the         molten material to convert at least a portion of one or more         feed fuel to syngas,     -   at least one supply conduit for delivering the syngas to the         exterior of the crucible.

-   102. Device according to item 102, wherein the liquid cooling     arrangement comprises passageways, the passageways being provided     within the body of the crucible.

-   103. Device according to item 102, wherein the passageways of the     liquid cooling arrangement are provided within a side wall of the     crucible.

-   104. Device according to item 102 or item 103, wherein the     passageways of the liquid cooling arrangement are provided within a     bottom wall of the crucible.

-   105. Device according to one of the items 101 to 104, the liquid     cooling arrangement comprising hollow conduits, the hollow conduits     surrounding an outer surface of the crucible.

-   106. Device according to one of the items 101 to 105, the liquid     cooling arrangement comprising at least one hollow conduit between     the crucible and an outer container which surrounds at least a part     of the crucible.

-   107. Device according to item 106, wherein the hollow conduit is     provided by an outer container which surrounds the crucible along     the bottom of the crucible and along the side walls of the crucible     up to at least half of the crucible's height.

-   108. Device according to item 6 or item 7, wherein a slag channel is     provided between a side wall of the crucible towards the exterior of     the crucible and the exterior of the hollow conduit.

-   109. Device according to one of the items 101 to 108, wherein the     coil is surrounded by an ELECTRICALLY insulating material.

-   110. Device according to one of the items 101 to 109, wherein the     coil is provided within a distance of 0 mm to 12 m to the side walls     of the crucible.

-   111. Device according to one of the items 101 to 110, wherein the     coil is a hollow coil or a solid COIL.

-   112. A device comprising:     -   a substantially metallic crucible which encloses a hollow with a         metallic surface for holding a metallic material in the hollow;     -   at least one heater, the at least one heater being disposed in         proximity to the metallic crucible, the at least one heater         being adapted to provide heating of the crucible,     -   a fluid cooling arrangement disposed in proximity to the         metallic crucible,     -   at least one feeding conduit, the feeding conduit extending         between the outside of the crucible and the inside of the         crucible,     -   at least one supply conduit, the supply conduit extending         between the inside of the crucible and the outside of the         crucible.

-   113. A device, comprising:     -   a holder unit with a metallic surface that defines a hollow for         holding a molten metallic material;     -   at least one heater unit disposed in proximity to the holder for         heating the hollow,     -   at least one feeder unit for providing a flow stream of one or         more combustible material to be delivered into the hollow,     -   a cooler unit for cooling the holder, the cooler unit being         disposed in proximity to the holder,     -   at least one supply means for delivering a gas from inside the         crucible to the outside of the crucible.

-   114. A gasification method for converting one or more feed fuel to     syngas, comprising:     -   placing an electrically conductive material within a metallic         crucible;     -   heating the electrically conductive material to form a molten         material disposed within the metallic crucible and maintaining         the molten material in a molten state;     -   cooling at least a portion of the crucible with a cooling         liquid;     -   delivering a flow stream of the one or more feed fuel into         contact with the molten material, thereby converting at least a         portion of the one or more feed fuel to syngas;     -   extracting the syngas from the crucible.

-   115. Gasification method according to item 14, further comprising     the cooling of the body of the crucible.

-   116. Gasification method according to item 114 or item 115, further     comprising the cooling of the outer surface, INTERIOR SURFACE, OR IN     COMBINATION of the crucible.

-   117. Gasification method according to one of items 114 to 116,     comprising controlling a temperature of the cooling liquid to lie     within a predetermined temperature range.

-   118. Gasification method according to one of the items 114 to 117,     wherein the cooling of the crucible comprises circulating the     cooling liquid.

-   119. Gasification method according to item 118, wherein the     circulating of the fluid comprises exchanging heat from the liquid     to one or more heat exchanger and recirculating the liquid to the     crucible.

-   120. A method comprising:     -   placing a metallic material within a hollow such that it is in         contact with a metallic surface of the hollow;     -   melting the metallic material to form a molten metallic material         and maintaining the molten metallic material in a molten state;     -   cooling the metallic surface with a fluid;     -   bringing one or more flow stream of one or more         hydrocarbon-containing material into contact with the molten         metallic material;     -   extracting reaction gas from the hollow.

-   121. A method for refining or processing hydrocarbons in an oil     refinery plant, comprising:     -   placing a metallic material within a hollow such that it is in         contact with at least a part of the interior wall surface of the         hollow,     -   melting the metallic material to form a molten metallic material         and maintaining the molten material in a molten state,     -   bringing one or more flow stream of one or more feed fuel         material into contact with the molten metallic material,     -   extracting reaction gas from the hollow.

-   122. Method according to item 121, wherein reaction gas is combusted     with an oxidant gas to generate thermal heat.

-   123. Method according to item 120 or item 121, wherein the thermal     heat is recovered from extracted reaction gas from the hollow or     from the combusted reaction gas to perform refining or processing of     hydrocarbons into a plurality of refined or processed hydrocarbon     products.

The molten metal in the crucibles of the above described embodiments can comprise metals that are typical for solder alloys, such as Sn, Zn, Cu, Pb, Sb, Bi, and In, if the embodiment includes the conversion of organic material into Syngas. In further embodiments, any metal or alloy, such as steel or brass, can be refined with the methods of the application.

In the above described embodiments, the crucible metallic material can be chosen to be identical to the electrically conductive charge material.

In further embodiments, the crucible metallic material can be an alloy of the electrically conductive charge material.

For example, the electrically conductive charge material is tin, a tin alloy, or a combination, and the crucible is made of a stainless steel material, a stainless steel alloy material, a tungsten material, or tungsten alloy material. Under oxidizing, reducing environments during which chemical, thermo-conversion of the feed fuel material into syngas, the choice of the crucible material will determine overall durability of the crucible during the intended operational lifetime of the present invention.

The use of tin or tin alloy can be useful, since its low melting point temperature range reduces energy expenditure to convert and melt the electrically conductive charge into its molten or liquid metal form.

Further, tin or tin alloy can reduce the sulfur content in the resultant syngas. Additionally, when the tin or tin alloy charge material is converted or melted into its molten form, its viscosity and wettability characteristics are better when utilized with crucibles made of a different metal or metal alloy material.

For example, tin or tin alloy can be utilized as the electrically conductive charge material in the metallic or substantially metallic crucible as the optimal arrangement so as to reduce energy expenditure to convert the electrically conductive charge into a melt, the molten form of the said charge material, its preferred reactivity potential with the crucible material, its viscosity during fluid introduction of feed fuel during operation.

It should also be noted that while tin or tin alloy is described, other types of electrically conductive charge material are used, such as cast iron, iron, iron alloys, copper, tin, lead. etc.

In the above described embodiments, the crucible can be substantially metallic and can have one or more hollow passageways or conduits to allow a circulating cooling fluid to flow within to regulate and control the material temperature of the crucible, and also to cause a thin or determined layer of the molten electrically conductive charge material to be semi-solidified so as to cause a protective layer to be formed to increase and enhance the overall operational lifespan of the crucible.

Different from metallic crucibles, refractory crucibles, due to their lower thermal conductivity inherent in their material and chemical composition make-up, cannot allow this semi-solidified layer to be formed and maintained easily given the diverse operating environment that is present within the molten charge material residing within the crucible during operation.

REFERENCES

-   1. “Feeding and Risering Guidelines for Steel Castings”, Steel     Founder's Society of America 2001, a publication supported by the     U.S. Department of Energy (DOE) Award No. DE-FC07-98ID13691. -   2. Heat Treating, Vol 4, Metals Handbook, 9th ed., American Society     for Metals, 1982 -   3. R. F. Haimbaugh, Induction Heat Treating, ASM International, 2006 -   4. Induction Heating Guide, Inductoheat Banyard (Pres.) 2003 -   5. J. Kassakian, M. Schlecht, G. Verghese, “Principles of Power     Electronics”, Addison-Wesley, 2001 -   6. Advanced Melting Technologies: (November 2005 Energy Saving     Concepts and Opportunities for the Metal Casting Industry BCS,     Incorporated 5550 Sterrett Place, Suite 306 Columbia, Md. 21044 -   7. Information Brochure of Inductotherm Safety Information: An     Inductotherm Group Company. -   8. “Induction Furnace—A Review”, Vivek R. Gandhewar et     al./International Journal of Engineering and Technology Vol. 3 (4),     2011, 277-284 -   9. “Metal Casting—A General Review”, Pelagia Research Library,     Advances in Applied Science Research, 2011, 2 (5): 360-371, ISSN:     0976-8610, CODEN (USA): AASRFC, and “Casting Processes” ME 4210:     Manufacturing Processes and Equipment, Prof J. S. Colton, Georgia     Institute of Technology. -   10. Tulsa Centrifugal Casting Machines LLC, product catalog     featuring casting machines model VP1000, VP1200 and VP500. -   11. IPT Workshop BTL—“Biomass to Liquid” R. C. Souza Feb. 26, 2008,     Dow Gas Cleaning. -   12. “Selective Hydrogenation in Steam Cracking”, Dr. Michael Bender,     BASF SE D-67056 Ludwigshafen, Germany, 21st Annual Saudi-Japan     Symposium Catalysts in Petroleum Refining & Petrochemicals King Fand     University of Petroleum & Minerals Dhahran, Kingdom of Saudi     Arabia—November 2011, ISBN 978-3-941721-07-4. -   13. “AVAILABLE AND EMERGING TECHNOLOGIES FOR REDUCING GREENHOUSE GAS     EMISSIONS FROM THE PETROLEUM REFINING INDUSTRY”, October 2010,     Office of Air and Radiation, United States Environmental Protection     Agency, Prepared by: Sector Policies and Programs Division Office of     Air Quality Planning and Standards U.S. Environmental Protection     Agency Research Triangle Park, N.C. 27711. -   14. “Analysis of Standards Options For Evaporative Coolers”, Gary B.     Fernstrom, PG&E, Prepared by Davis Energy Group, Energy Solutions     May 11, 2004. -   15. “Size Reduction and Size Enlargement”, authored by Richard H.     Snow, Ph.D., Engineering Advisor, IIT Research Institute; Member,     American Chemical Society, Sigma Xi; Fellow, American Institute of     Chemical Engineers. (Section Editor), Terry Allen, Ph.D., Senior     Research Associate (retired), DuPont Central Research and     Development. (Particle Size Analysis), Bryan J. Ennis, Ph.D.,     President, E&G Associates, and Adjunct Professor of Chemical     Engineering, Vanderbilt University; Member and Chair of Powder     Technology Programming Group of the Particle Technology Forum,     American Institute of Chemical Engineers. (Size Enlargement),     James D. Litster, Ph.D., Associate Professor, Department of Chemical     Engineering, University of Queensland; Member, Institution of     Chemical Engineers-Australia. (Size Enlargement). -   16. “Liquid Phase Methanol (LPMEOH™) Project Operational     Experience,” Heydorn, E. C., Street, B. T., and Kornosky, R. M.,     (Presented at the Gasification Technology Council Meeting in San     Francisco on Oct. 4-7, 1998).

Reference number list  10 gasifier  10′ gasifier with tilted crucible  30 bottom floor (G30b)  31 cylindrical side wall  32 hollow region (GH01)  33 inner bottom surface  40 metallic crucible  41 cylindrical shell  42 shell bottom (G30a)  43 reactor vessel (G10)  44 internal lateral surface (G40b)  45 shell side wall (G40a)  50 feed conduit (G50a)  51 feed conduit (G50b)  52 overhead lance conduit  53 feed conduit  54 cover flap  60 cover  80 passage line (80b)  81 syngas stream (80a)  90 melt  91 metal comprising material  101 slag granulation unit (SG 1)  102 slag granulation unit (SG 2)  103 slag granulation unit (SG 3)  110 slag channel  120 induction coil (IC 30)  140 downstream application conduit  141 gas input feeder (GIF 1)  142 outer container  143 dielectric cooling fluid  144 cooling fluid inlet  145 cooling fluid outlet  146 cooling fluid  151 power lines (PS 01)  210 cooling fluid supply conduit (GT 10)  211 passageway (GT 10b)  212 cooling fluid discharge conduit (GT 10a)  213 cooling fluid supply conduit (GT 10c)  214 passageway  215 cooling fluid discharge conduit  216 cooling fluid stream  217 cooling fluid stream  220 insulating material (IN 20)  221 insulating jacket  310 hollow cooling conduits (HT10)  501 heat exchanger section (HE 01)  510 remote site (G10)  511 injector (FD1)  512 air compressor (FD2)  521 syngas cooler (HE 01)  530 processed syngas outlet (30)  531 syngas  540 gasifier train  601 process heater (GX 01) (heat exchanger)  602 process heater (GX 02)  603 process heater (GX 03)  604 process heater (GX 04)  605 process heater (GX 05, GX 01 of FIG. 9)  606 process heater/fired heater (GX 06)  607 process heater  608 burner  609 heat exchanger 1000 refinery plant (100) 1000′ refinery plant (100) 1010 crude oil, hydrocarbon process fluid (10) 1200 vacuum distillation column 1201 atmospheric distillation section (10) 1202 receiving portion 1203 column portion 1204 outlet 1205 syngas conduit 1206 inlet 1207 discharge material conduit 1208 distillation column outlet 1209 first generator 1210 second generator 1211 first sensor 1212 first process controller 1213 second sensor 1214 second process controller 1215 side stripper 1216 extraction pumps 1217 pump around pump 1218 residue pump 1219 recirculation pump 1220 pump 1221 gas turbine 1222 heat exchanger 1300 hydrocracking plant (10) 1310 primary hydrocracking reactor (HR10) 1311 feed conduit 1312 recycling conduit 1320 first pass hydrocracking reactor (HR20) 1321 effluent outlet 1330 second pass hydrocracking reactor (HR 30) 1331 effluent outlet 1340 high pressure separator 1341 high pressure amine absorber 1342 low pressure separator 1350 make-up compressor (CMP 10) 1351 make up hydrogen input 1360 recycle compressor (CMP 20) 1361 recycle compressor inlet 2020 gas compressor (G20) 2050 flue gas conduit 2051 overhead lance 2060 pressurized flue gas stream (G60) 2061 pressurized flue gas stream (G60) 2070 gas accumulator plant (G70) 2110 combustion power plant (G210) 2111 flue gas (G210 A) 

1. A gasification device for converting one or more feed material into syngas, comprising: a crucible for holding an electrically conductive material; at least one electric heater in the vicinity of the crucible, the at least one electric heater supplied with electricity to generate heat so as to cause melting and heating of the electrically conductive material to form a molten melt material disposed within crucible, a cooling arrangement for the crucible, at least one conduit for providing a flow stream of one or more feed material to be delivered and placed into fluid contact with molten melt material to convert at least a portion of one or more feed material into syngas, at least one conduit for delivering syngas to the exterior of the crucible.
 2. The gasification device according to claim 1, wherein at least a part of the crucible is made of an electrically insulating material.
 3. The gasification device according to claim 1, wherein at least a part of the crucible is made of a metallic material.
 4. The gasification device according to claim 1, wherein at least a part of the crucible is made of an electrically insulating crucible material and interposed with a metallic crucible material.
 5. The gasification device according to claim 1, wherein at least a part of the cooling arrangement comprising one or more hollow conduits is placed in contact with the metallic material portion of crucible.
 6. The gasification device according to claim 5, wherein the one or more hollow conduits are supplied a cooling agent from one or more prime mover apparatus from at least one remote site.
 7. The gasification device according to claim 6, wherein the cooling agent is supplied to flow within the one or more hollow conduits at a determined flow pressure range.
 8. The gasification device according to claim 6, wherein the cooling agent is supplied to flow within the one or more hollow conduits at a determined flow velocity range.
 9. The gasification device according to claim 6, wherein the cooling agent is supplied to flow within the one or more hollow conduits at a determined flow temperature range.
 10. The gasification device according to claim 1, wherein at least a portion of the electric heater is in fluid contact with the molten melt material.
 11. The gasification device according to claim 1, wherein the electric heater is not in fluid contact with the molten melt material.
 12. The gasification device according to claim 6, wherein the cooling agent is supplied to flow within the one or more hollow conduits at a determined cooling agent flow velocity range, at a determined cooling agent flow pressure range, at a determined cooling agent flow pressure range so as to cause the metallic portion of the crucible to be operating within a temperature range of between 100 degree Celsius to 800 degree Celsius.
 13. The gasification device according to claim 12 wherein the cooling agent is supplied to flow within the one or more hollow conduits in a manner so as to cause at least a portion of the molten melt material disposed within crucible to be in a substantially solid phase.
 14. The gasification device according to claim 12 wherein the cooling agent is supplied to flow within the one or more hollow conduits in a manner so as to cause at least a portion of the molten melt material contacting the interior surface area of the crucible to be in a substantially solid phase.
 15. The gasification device according to claim 1, wherein at least one remote prime mover device is in operational communication with the at least one conduit to cause flow stream of one or more feed material to be delivered and placed into fluid contact with molten melt material.
 16. The gasification device according to claim 15, wherein the flow stream of one or more feed material is delivered at an absolute flow pressure range that is equivalent or greater than the determined fluid hydrostatic pressure of the molten melt material disposed within crucible.
 17. The gasification device according to claim 1, wherein the at least one electric heater is supplied with electricity to cause melting and heating of the molten metal material to a temperature range of between 800 to 2000 degree Celsius.
 18. The gasification device according to claim 1, wherein the at least one electric heater is not in contact with the metallic material portion of the crucible.
 19. The gasification device according to claim 1, wherein at least a portion of the at least one electric heater is interposed with an electrically insulated material.
 20. A gasification method for converting one or more feed material into syngas, comprising: placing an electrically conductive material within a crucible; melting and heating the electrically conductive material to form a molten melt material disposed within the crucible and maintaining the molten melt material in a molten state at a temperature range of between 800 degree Celsius to 2000 degree Celsius; cooling at least the metallic material portion of the crucible to a temperature range of between 100 degree Celsius to 800 degree Celsius so as to cause a portion of the molten melt material in fluid contact with at least a part of the interior surface of the crucible to be solidified; delivering a flow stream of one or more feed material into fluid contact with the molten melt material at a flow stream absolute fluid pressure range that is equivalent or greater than the determined fluid hydrostatic pressure of the molten melt material; extracting the syngas from the crucible. 21-23. (canceled) 